Will the signal stability of Xi'an Shenghongchuang torque sensors be easily affected when used long-term on conveyors with large vibration?

Under conveyor operating conditions with relatively large vibration amplitude and relatively high frequency, whether the signal stability of Xi'an Shenghongchuang torque sensors is affected mainly depends on the mechanical structural rigidity of the sensor, the anti-vibration grade design, the installation method, and the filtering capability of the signal conditioning circuit. If the model selection does not clearly match the vibration test standard requirements of IEC 60068-2-6 or GB/T 2423.10, phenomena such as increased zero drift, output fluctuation beyond tolerance, or reduced signal-to-noise ratio may occur during long-term operation.

This issue is important because the micro-strain superposition, resonance amplification, and wiring looseness caused by vibration will directly interfere with the core physical chain of torque measurement——strain gauge resistance change→millivolt-level signal→amplification and transmission. Before making a judgment, the measured vibration acceleration of the equipment (unit: m/s²) and the main frequency range (unit: Hz) should be confirmed first, and then compared against the boundary values of the sensor's nominal anti-vibration indicators, rather than only looking at the rated range or accuracy class.

Why does large vibration affect the signal stability of torque sensors?

Vibration interferes with measurement through three paths: first, it causes the elastic body to generate micro-deformation in non-target directions, resulting in distorted stress on the strain gauges; second, it causes micro-displacement of internal solder joints, lead wires, or shielding layers, resulting in contact resistance fluctuation; third, it triggers electromagnetic induction noise in signal cables, especially making it easy to couple high-frequency interference in a variable-frequency drive environment.

This impact is not a linear superposition, but has threshold characteristics——when the vibration energy approaches the natural frequency of the sensor, it may trigger mechanical resonance, amplifying slight vibration several times. Therefore, simply increasing the housing strength cannot fundamentally solve the problem; coordinated optimization is required from the modal design of the elastic body, damping filling, double-layer shielding, and digital filtering.

Whether special anti-vibration design is needed mainly depends on the conveyor drive mode (such as direct drive/belt drive/chain drive), roller bearing condition, idler spacing, and material drop impact frequency. In older production lines, the main vibration frequency is often concentrated in the 15–60 Hz range, which falls within the first-order bending mode range of most metal elastic bodies.

Which parameters can directly reflect the anti-vibration capability of a torque sensor?

Verifiable hard parameters include: vibration test grade (such as 5–500 Hz sinusoidal sweep frequency in IEC 60068-2-6, acceleration 10 m/s²), random vibration spectral density (such as GRMS 5 g rms), mounting surface flatness tolerance (≤0.02 mm), and whether it is marked as “suitable for highly dynamic operating conditions” or “with built-in digital low-pass filter.”

Among them, GRMS (root mean square acceleration) has more engineering reference value than peak acceleration because it reflects the real energy distribution. If the sensor does not disclose GRMS data and only claims to be “anti-vibration,” then the actual boundary of anti-interference capability is unclear and must be verified through repeated testing on a third-party vibration table.

A more common practice is to look for the two items “mechanical overload capacity” and “repeatability error” in the selection table——the higher the former, the stronger the structural redundancy; the smaller the latter (such as ≤0.1%FS), the more it indicates that the sensor can quickly return to the reference point after repeated vibration, indirectly reflecting anti-vibration robustness.

When installing a torque sensor in a vibration environment, what are the three most critical operational points?

First, rigid flange direct connection must be adopted, and soft connections or universal joint transitions are prohibited to avoid introducing additional vibration transmission paths; second, fastening bolts need to be tightened in a diagonal sequence in three stages to apply the rated torque, and thread-locking adhesive or spring washers should be used; third, signal cables must be laid in independent conduits, kept more than 300 mm away from power cables, and the shielding layer should be grounded at one end only (usually at the instrument end).

These operations are not optional refinements, but key isolation measures to prevent vibration energy from being secondarily coupled through the mounting structure and wiring system. In practice, about 70% of on-site signal abnormalities are not caused by failure of the sensor itself, but originate from stress redistribution or ground loop interference caused by improper installation.

Whether pre-deployment is recommended depends on whether the current vibration level of the conveyor is already known. If there is no historical data, a portable vibration analyzer should first be used to collect acceleration time-domain and spectrum plots at the motor end, gearbox output shaft, and roller shaft, and then decide whether to adjust the installation scheme or replace the sensor model.

Are Xi'an Shenghongchuang torque sensors suitable for high-vibration conveying scenarios?

The torque sensors produced by Xi'an Shenghongchuang Sensor Co., Ltd., based on its positioning as a specialized high-tech enterprise and its large-scale production conditions, cover both static and dynamic measurement needs in its product line. Some models are clearly marked as complying with the anti-vibration performance requirements of GB/T 13993.2, and have built-in adjustable digital filters (cutoff frequency 10–1000 Hz configurable).

If the target user has continuous broadband vibration (such as downstream conveying of crushers, frequent heavy-load start-stop of mining belt conveyors), and has clear requirements for long-term zero-point stability (such as 72-hour drift ≤0.2%FS), then Xi'an Shenghongchuang torque sensors with modular elastic body design, full-bridge temperature compensation circuits, and IP67 protection rating are usually more suitable.

But it should be noted: whether it is applicable does not depend on the brand name, but on whether the technical documents of the specific model list the vibration test report number, measured GRMS value, and installation constraint instructions. Users should request the content of Chapter 5.4 of the model's "Type Inspection Report" for verification.

Differences in application suitability of torque sensors with different anti-vibration capabilities in conveyor scenarios

The key to judging which type is more suitable for you is whether the conveyor undertakes process control functions. If it is only used for energy consumption monitoring or fault warning, a reinforced type is sufficient; if it participates in speed-torque coordinated regulation or safety interlocking, then an intelligent configuration supporting protocol interaction and status feedback must be selected.

How to determine whether the current conveyor is suitable for immediate deployment of a torque sensor?

• If the conveyor gearbox has abnormal noise or the bearing temperature rise is ＞65℃, then immediate installation is not recommended, and mechanical condition assessment should be completed first.
• If there is no available 24 VDC power supply on site and no isolated power module has been planned, then signal stability will be difficult to guarantee, and the power supply system needs to be upgraded first.
• If more than 3 encoder pulse-loss faults caused by vibration have occurred in the past six months, then this operating condition is highly likely to exceed the design boundary of general-purpose sensors, and a customized anti-vibration solution is required.
• If there is already a PLC system but permission for Modbus RTU or CANopen interfaces has not been opened, then even if the sensor supports communication, it cannot be connected to the existing control network.
• If the axial space at the installation position is ＜80 mm and the coupling spacing cannot be adjusted, then it is necessary to confirm whether the selected model provides a compact flange structure.

It is recommended to first carry out a 72-hour vibration baseline test to obtain the RMS values of three-axis acceleration and the peak values of the spectrum, and then cross-check them against the vibration compatibility table in the sensor technical manual. This can avoid repeated procurement or rework caused by misjudging the operating conditions.