What it is

Torque flange sensors with integrated speed measurement and a high-resolution angle of rotation measuring system, with analog and digital interfaces for easy integration into test bench environments.

The Kistler 4552A KiTorq Rotor is a strain gage torque measuring flange for highly dynamic torque on test benches, rated from 443 to 88,508 lbf·in (50 N·m to 10 kN·m). Paired with a KiTorq Stator, it samples at about 35 kS/s with a 10 kHz cut-off, measures speed or angle, and outputs frequency, voltage, or fieldbus signals. Speeds reach 30,000 rpm, and linearity including hysteresis is <±0.03 %FSO.

• Rated torque: 443 … 88,508 lbf·in (50, 100, 200, 500 N·m; 1, 2, 3, 5, 10 kN·m)
• Accuracy class 0.05 in the single range; linearity incl. hysteresis <±0.03 %FSO
• Dynamic: approx. 35 kS/s sampling
• High-speed applications: up to 30,000 rpm (max., H option, 50 N·m … 1 kN·m)
• Rotational speed or angle measurement: 60, 128, or up to 8,192 pulses per revolution
• Outputs: 240 ±120 kHz frequency, ±10 V voltage, optional PROFINET, EtherCAT, EtherNet/IP, PROFIBUS, or CANopen
• Standard flange dimensions: connection to DIN ISO 7646 (gear flanges)
• Easy installation: up to 0.20 in (5 mm) radial distance between rotor and stator
• Static and dynamic measurements: cut-off frequency (−3 dB) of 10 kHz

What it is used for

Some of the use cases for the 4552A include:

• Electric motor test benches — torque and speed on e-drive testing
• Gearbox test benches — input and output torque
• Pump test benches — drive torque measurement
• Combustion engine test benches — highly dynamic torque

Main features / advantages

What does the 4552A measure?

The torque flange sensors of Type 4552A come with integrated speed measurement and a high-resolution angle of rotation measuring system. The analog and digital interfaces provide maximum flexibility and easy integration into various test bench environments.

The KiTorq system is a torque measuring flange system consisting of the Type 4552A KiTorq Rotor torque measuring unit and the Type 454xB KiTorq Stator torque evaluation unit. The rotors and stators of the KiTorq system can be used in any combination with each other without additional calibration. Using the ordering key, the Type 4552A rotor can be purchased individually or as a calibrated torque measurement chain together with a KiTorq Stator. The stator automatically detects a change of rotor and sets the required parameters. The torque evaluation unit supplies power to the KiTorq Rotor and receives measured values from it. It has integrated speed or angle detection and provides different signal outputs depending on the version.

All KiTorq rotors capture torque using strain gages. The signal is amplified and processed at approximately 35 kS/s, which gives very high dynamic torque measurement. SensorTool is free parameter software that connects the 4552A to a PC.

Why engineers pick it

• Highly dynamic torque. About 35 kS/s sampling and a 10 kHz cut-off frequency capture fast torque events, with group delay below 0.22 ms.
• Accurate in two ranges. Single range reaches accuracy class 0.05; dual-range calibration at 1:5 or 1:10 reaches class 0.1 in the lower range.
• Interchangeable rotors and stators. Each rotor and stator has its own calibration certificate, so virtual calibration values for a new combination can be calculated from the individual certificates.
• Fieldbus-ready. Stator options output PROFINET or EtherCAT at up to 4,000 values/s, or EtherNet/IP, PROFIBUS, and CANopen at up to 1,000 values/s.

Which 4552A configuration do I need?

Stator:

• S00: rotor only
• S10: KiTorq stator
• Fieldbus stators: PROFINET (S2A), PROFIBUS (S2B), CANopen (S2C), EtherCAT (S2D), or EtherNet/IP (S2E)

Speed/angle:

• N1: 1 × 60 pulses/rev
• N2: 2 × 128 pulses/rev + Z
• N3: up to 2 × 8,192 pulses/rev + Z

Speed range: low (L) or high (H).

Calibration:

• WKS 1 or WKS 2: single range, or dual range at 1:10 or 1:5
• DAkkS: 5 or 8 measuring points, single or dual range. Dual-range DAkkS (D51, D52, D81, D82) is not available on the 10 kN·m size.

Measuring ranges for special calibration can be freely defined in 5% increments.

How is the 4552A installed?

The rotor bolts into the drive line between the drive and the loading machine, with couplings and adapter flanges (Type 2305A, on request). The stator mounts on a bracket around the rotor. Keep the metal-free space around rotor and stator clear: any metal can disturb energy transmission and cause signal disturbance. Observe the maximum mounting depth of the rotor screws and the permitted air gap between rotor and stator.

When is the 4552A the wrong choice?

• Angle resolution at high speed. At 8,192 pulses per revolution, the 500 kHz output limit caps speed at 3,660 rpm.
• Wet or dirty environments. The system is rated IP54.
• Combined parasitic loads. Bending moment, longitudinal force, and transverse force are each permitted up to their limit only when the others are absent. With 30% of bending moment and transverse force acting together, only 40% of the longitudinal limit is permitted.
• Long signal cables. The recommended maximum cable length for signal quality is 16.4 ft (5 m).

Configure and order the 4552A

Configure the 4552A by rated torque, stator, speed/angle option, speed range, and calibration, and order directly on this page. For questions, contact us.