Torque Measurements Research Articles

Devising a technique for assessing the accuracy of measuring electric motor torque

The object of this study is a technique for assessing the accuracy of measuring the torques of electric motors. This technique is based on the improvement of dynamic torque measurement processes under transient operating modes. Special attention was paid to devising adaptive methods to normalize the output signal, which take into account vibrations and nonlinearities of the measuring channel. In order to improve the accuracy of measurements under conditions when the controlled parameter has different deviations from its average value, a technique for integrating time measurement intervals was proposed. That has made it possible to generalize parameter fluctuations, providing more stable measurement results. This paper reports the simulation of the process of measuring torques of electric motors under transient operating modes and under vibration conditions. That has made it possible to test the proposed technique for estimating the variance of the methodological error, which includes the integration of measurement time intervals and makes it possible to increase the accuracy of the measurement under the conditions of transient modes in electric motor operation. An algorithm for correcting the error of the dynamic torque of the electric motor has been proposed, which allows it to be corrected. This becomes possible owing to the use of a reference measure and the proposed technique for determining the deviations of the controlled parameter of the measured quantity, as well as the automatic calibration of measuring transducers. The algorithm allows for flexible settings of the corrective action, expanding the potential of electric motor control systems. It can complement soft measurement methods, as well as adjust the threshold values of deviations under different operating modes of electric motors. This allows the measured systems to better adapt to changes in operating conditions, to adjust the specified measurement accuracy under conditions of uncertainty

Drag reduction performance of discrete superhydrophobic surfaces in von Kármán swirling flow

Enhancing the energy efficiency and mitigating environmental pollution in maritime transportation relies significantly on minimizing frictional drag of ships. In this study, we employ wettability dividing lines and convex stripes to discretize the continuous air layer on superhydrophobic surfaces, offering a mechanism to enhance their drag reduction efficacy. Initially, we theoretically analyze the stabilization of the air layer on superhydrophobic surfaces through wettability dividing lines and convex stripes. Subsequently, torque measurements are conducted to characterize drag reduction performance in von–Kármán swirling flow. The drag reduction parameters that performed optimally were determined experimentally by parametric analysis, with a 20–mm spacing identified for the hydrophilic ring on the wettability difference surface, and a 20–mm spacing with a 2–mm height for the convex stripe on the superhydrophobic surface. Under these specified parameter values, the maximum Reynolds number for effective drag reduction (Rec) increases from 1.62 × 105 to 3.24 × 105, and the drag reduction rate at Rec = 3.24 × 105 reaches 32.29% and 26.61%, respectively. Moreover, coupling wettability dividing lines with superhydrophobic convex stripes further enhances Rec to 4.05 × 105, and the drag reduction rate stabilizes at around 30% within the maximum Reynolds number.

Research on the calculation and evaluation method of transmission efficiency of noncircular planetary gear

The torque fluctuation characteristics of noncircular planetary gear (NPG) systems are difficult to obtain, and there is no clear analysis method and evaluation method for transmission efficiency, which seriously affects their service performance. Given that, this article establishes a torque fluctuation model for NPG systems based on the principle of gear meshing and differential geometry theory and methods, taking into account factors such as actual working conditions and speed loads. And proposed, the comprehensive transmission rate, a new method for evaluating the efficiency of NPG systems. By analyzing the actual working conditions of NPG systems, the influence mechanism of alternating load and speed on torque fluctuation and transmission efficiency was explored. The research results indicate that the alternating load can cause an increase in system impact and vibration. The comprehensive transmission rate of NPG systems decreases with increasing rotational speed and increases with increasing load, and is more sensitive to changes in rotational speed. The trend of comprehensive transmission rate and transmission efficiency of NPG systems is basically consistent, indicating that the proposed method of using comprehensive transmission rate to evaluate transmission efficiency is a practical and feasible analysis method. The research results can provide a new method for dynamic measurement and evaluation of torque and transmission efficiency of non-circular gear transmission systems.

Discrete element modelling of rotary CPT and its applications

The cone penetration test (CPT) is a major in-situ testing with advantages in efficiency, reliability, and continuous measurement. However, it is often limited in penetration depth in soils such as dense sand and gravel due to high resistance and insufficient pushing force. Studies have shown that rotation can reduce penetration resistance, leading to the development of the rotary CPT. In addition, the torque measurement in rotary CPT could potentially provide extra information for soil behavior. This study simulates regular and rotary CPT tests with varied confining pressure and initial relative density using the discrete element method (DEM). Macroscale results verify that rotation can improve the penetrability of CPT by reducing vertical soil resistance. The reduction mechanism was explained by the microscopic observations and theoretical calculations that rotation can reduce the magnitude of the contact force and tilt its main direction horizontally. To advance the application of rotary CPT, a strong linear correlation between the measurements in rotary and regular CPTs was established, enabling interpretation of the rotary CPT measurements via the vast knowledge accumulated for regular CPT soundings. Furthermore, a theoretical derivation was developed to calculate the soil-probe interface friction coefficient directly by using the measurements of rotary CPT. The influence of the confining pressure, probe friction coefficient, and rotational speed ratio on the calculation accuracy are discussed and explained via particle-scale observations.

Reduction of Disk Friction Loss by Applying a Fin to the Back of a Centrifugal Impeller

Abstract It is well known that the ratio of disk friction loss of low specific speed pumps is large. When the specific speed is 100 min−1, m3/min, m or less, the disk friction loss increases remarkably. In this study, focusing on the clearance flow from the diffuser outlet to the impeller outlet (This is called the outward flow) behind the centrifugal pump, a fin was installed on outer diameter side of the rotating wall on the back side of a centrifugal pump as a countermeasure, and the influence of changes in velocity distribution near the wall on disk friction loss was investigated by torque measurements, velocity measurement, and computational fluid dynamics (CFD) analysis. As a result, it was clarified that disk friction loss is decreasing by installing the fin in both torque measurements and CFD results, because the clearance flow is separated by fin and circumferential velocity is increased in the wake region of the fin in both measurements and CFD. In addition, it was clarified that disk friction coefficient (normalized torque) can be expressed as a function of the inlet swirl ratio and Reynolds number. Also, prediction equation is derived for each shape (with and without fin). According to the equation, it was found that disk friction loss reduction effect by installing a fin becomes larger when Reynolds number and the inlet swirl ratio are small.

An experimental study of the thrust and power produced by a 1/20th scale tidal turbine utilising blade winglets

Winglets have been employed in the aviation industry to reduce vortices generated at aircraft wings, decreasing drag, and hence increasing fuel economy. For rotating applications previous experimental and numerical studies addressed the application for wind turbines and suggested winglets facing backwards on the suction side of a blade could increase the power capture. This paper presents experimental work using a scale 3-bladed horizontal axis tidal turbine. An oil-based paint flow visualisation coupled to blade thrust and torque measurements helped to identify the mechanism behind the phenomenon affecting the performance of winglets facing the suction side of a turbine blade. The results show that on average a winglet facing downstream decreases the power coefficient 1–2% and increases the thrust coefficient up to 6% for tip speed ratios 5.0–7.0. On the other hand, a symmetrically mirrored winglet facing upstream increased the power coefficient by 1–2%, and the thrust coefficient by 3–4%. Winglets have the potential to provide a meaningful increase to power capture at minimal additional capital cost without increasing rotor diameters. Further work to optimize pressure‐side winglets should be conducted.

Evaluation of the Correlation Between the Structural Parameters of Trabecular Bone in CBCT and the Primary Stability of Dental Implants.

To investigate the relationship between the structural parameters of trabecular bone obtained from CBCT imaging and the primary stability of dental implants. Sixty patients underwent implant placement followed by primary stability evaluation via measurement of the insertion torque (IT) and the implant stability quotient (ISQ). Gray values (GV) and the fractal dimension (FD) were also measured using pretreatment CBCT images. FD values showed a positive and significant relationship with ISQ and IT values (P = .017 and P = .004, respectively). Additionally, there was a positive and significant correlation between GV and IT (P = .004) as well as between GV and ISQ (P = .010). FD and GV showed a considerable difference between the maxillary and mandibular jaws and were higher in the mandible. Only FD was significantly different between men and women and was higher in men. In the two age groups (older and younger than 45 years), only GV was considerably higher in people older than 45 (P < .05). Both fractal dimension and gray values obtained from CBCT are efficient methods for predicting the primary stability of the implant due to their relationship with ISQ and IT values.

Measurement of Implant Insertion Torque in Intentionally Undersized Osteotomy Site Preparation in the Posterior Maxilla: A Prospective Clinical Study.

Achieving adequate primary stability for dental implants in the posterior maxilla is challenging due to the area's low bone density and fine trabecular bone. Low primary implant stability can compromise the long-term success of the implant. This study aims to evaluate the effect of intentionally undersized osteotomy sites on the insertion torque of implants placed in type 4 bone density in the posterior maxilla, regardless of the surgeon's tactile sense of the bone density. The conventional implant placement technique was performed in the posterior maxilla by intentionally omitting the last drill of the recommended drilling sequence protocol. The insertion torque was measured using an integrated surgical motor software. The study included 72 implants in patients of both genders and different age groups. The retrieved samples were divided into four groups, with insertion torque ranging from 11 Ncm to 48 Ncm. The mean insertion torque was 26.51 ± 0.18 Ncm for all cases (P = .001). No significant difference was found in the mean insertion torque between different age groups (26.51 ± 2.845, P = .84). However, a significant difference was observed between male and female cases (P = .84). Most implant insertion torque measurements vary significantly between cases in the intentionally underprepared posterior maxillary osteotomy site. The last drill should be omitted for all preparations of the posterior maxillary implant sites. Intentionally minimizing the osteotomy site is recommended for all posterior maxillary implant cases.

Impact of grease physical properties on the friction torque and service life of wheel bearings

Wheel bearings play a crucial role in ensuring the smooth and reliable rotation of wheels in automotive applications. Grease is commonly used as a lubricant in wheel bearings. The physical properties of grease, such as viscosity, base oil type, and thickener composition, significantly influence the overall performance and longevity of wheel bearings. This study investigates the impact of grease's physical properties on wheel bearing friction torque and service life. To evaluate the effects of different grease formulations, a series of experiments were conducted using a four-ball tester, rheometer, and a custom-built test rig to measure bearing frictional torque and service life. Multiple greases with varying viscosity grades, base oil types (mineral oil, synthetic oil), and thickener compositions (lithium, diurea, and polyurea) were tested under controlled operating conditions. Friction torque measurements were obtained using a high-accuracy torque sensor, while service life was determined by monitoring the bearing life in actual endurance testing. The results indicated that grease physical properties directly affected wheel bearing friction torque and service life. Low to Medium-viscosity greases generally exhibited 35–40% lower friction torque due to enhanced lubrication film formation and reduced metal-to-metal contact however, excessively high viscosity resulted in 50–60% higher frictional torque and thereby increased energy consumption. Different base oil types showed varying friction reduction and service life level, with mineral oil in some cases showed lower frictional torque around 30–40% particularly at high temperature but with significant reduction in the service life. Furthermore, the thickener composition significantly influenced grease performance. Based on these findings, selecting the appropriate grease with optimal physical properties is crucial for minimizing friction torque and extending the service life of wheel bearings.

Stage Separation Failure: Model Based Diagnostics and Prognostics

&#x0D; &#x0D; &#x0D; Safety of the next-generation space flight vehicles requires development of an in-flight Failure Detection and Prognostic (FD&amp;P) system. Development of such system is challenging task that involves analysis of many hard hitting engineering problems across the board. In this paper we report progress in the development of FD&amp;P for the re-contact fault between upper stage nozzle and the inter-stage caused by the first stage and upper stage separation failure. A high-fidelity models and analytical estimations are applied to analyze the following sequence of events: (i) structural dynamics of the nozzle extension during the impact; (ii) structural stability of the deformed nozzle in the presence of the pressure and temperature loads induced by the hot gas flow during engine start up; and (iii) the fault induced thrust changes in the steady burning regime. The diagnostic is based on the measurements of the impact torque. The prognostic is based on the analysis of the correlation between the actuator signal and fault-induced changes in the nozzle structural stability and thrust.&#x0D; &#x0D; &#x0D;

Wind turbine rotors in surge motion: new insights into unsteady aerodynamics of floating offshore wind turbines (FOWTs) from experiments and simulations

Abstract. An accurate prediction of the unsteady loads acting on floating offshore wind turbines (FOWTs) under consideration of wave excitation is crucial for a resource-efficient turbine design. Despite a considerable number of simulation studies in this area, it is still not fully understood which unsteady aerodynamic phenomena have a notable influence on the loads acting on a wind turbine rotor in motion. In the present study, investigations are carried out to evaluate the most relevant unsteady aerodynamic phenomena for a wind turbine rotor in surge motion. As a result, inflow conditions are determined for which a significant influence of these phenomena on the rotor loads can be expected. The experimental and numerical investigations are conducted on a two-bladed wind turbine rotor subjected to a tower-top surge motion. A specialised wind tunnel test rig has been developed to measure the aerodynamic torque response of the rotor subjected to surge motions with moderate frequencies. The torque measurements are compared to two free-vortex-wake (FVW) methods, namely a panel method and a lifting-line method. Unsteady contributions that cannot be captured using quasi-steady modelling have not been detected in either the measurements or the simulations in the covered region of motions ranging from a rotor reduced frequency of 0.55 to 1.09 and with motion velocity amplitudes of up to 9 % of the wind speed. The surge motion frequencies were limited to a moderate range (5 to 10 Hz) due to vibrations occurring in the experiments. Therefore, a numerical study with an extended range of motion frequencies using the panel and the lifting-line method was performed. The results from both FVW methods reveal significant unsteady contributions of the surge motions to the torque and thrust response that have not been reported in the recent literature. Furthermore, the results show the presence of the returning wake effect, which is known from helicopter aerodynamics. Additional simulations of the UNAFLOW scale model and the IEA 15 MW rotor demonstrate that the occurrence of the returning wake effect is independent from the turbine but determined by the ratio of 3P and surge motion frequency. In the case of the IEA 15 MW rotor, a notable impact of the returning wake effect was found at surge motion frequencies in the range of typical wave periods. Finally, a comparison with OpenFAST simulations reveals notable differences in the modelling of the unsteady aerodynamic behaviour in comparison to the FVW methods.

Lessons for future clinical trials in adults with Becker muscular dystrophy: Disease progression detected by muscle magnetic resonance imaging, clinical and patient-reported outcome measures.

Because Becker muscular dystrophy (BMD) is a heterogeneous disease and only few studies have evaluated adult patients, it is currently still unclear which outcome measures should be used in future clinical trials. Muscle magnetic resonance imaging, patient-reported outcome measures and a wide range of clinical outcome measures, including motor function, muscle strength and timed-function tests, were evaluated in 21 adults with BMD at baseline and at 9 and 18 months of follow-up. Proton density fat fraction increased significantly in 10/17 thigh muscles after 9 months, and in all thigh and lower leg muscles after 18 months. The 32-item Motor Function Measurement (MFM-32) scale (-1.3%, p = 0.017), North Star Ambulatory Assessment (-1.3 points, p = 0.010) and patient-reported activity limitations scale (-0.3 logits, p = 0.018) deteriorated significantly after 9 months. The 6-min walk distance (-28.7 m, p = 0.042), 10-m walking test (-0.1 m/s, p = 0.032), time to climb four stairs test (-0.03 m/s, p = 0.028) and Biodex peak torque measurements of quadriceps (-4.6 N m, p = 0.014) and hamstrings (-5.0 N m, p = 0.019) additionally deteriorated significantly after 18 months. At this timepoint, domain 1 of the MFM-32 was the only clinical outcome measure with a large sensitivity to change (standardized response mean 1.15). It is concluded that proton density fat fraction imaging of entire thigh muscles is a sensitive outcome measure to track progressive muscle fat replacement in patients with BMD, already after 9 months of follow-up. Finally, significant changes are reported in a wide range of clinical and patient-reported outcome measures, of which the MFM-32 appeared to be the most sensitive to change in adults with BMD.

High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation

A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed hollow tube and help us to find an optimal process design. Experimental trials show the significant effect of the axial material flow and the number of tools on the rotary swaging process. By taking these effects into account, successful form- and force-fit joining of the sensor carrying discs into the tube can be achieved. Successful joining of an optical sensor for bending force and torque measurement shows hysteresis-free sensory behavior and thus backlash-free joining of the sensor carrier discs. The paper concludes with a presentation of the results of a numerical study on a potential closed-loop approach to the joining process.

Shining Light in Mechanobiology: Optical Tweezers, Scissors, and Beyond.

Mechanobiology helps us to decipher cell and tissue functions by looking at changes in their mechanical properties that contribute to development, cell differentiation, physiology, and disease. Mechanobiology sits at the interface of biology, physics and engineering. One of the key technologies that enables characterization of properties of cells and tissue is microscopy. Combining microscopy with other quantitative measurement techniques such as optical tweezers and scissors, gives a very powerful tool for unraveling the intricacies of mechanobiology enabling measurement of forces, torques and displacements at play. We review the field of some light based studies of mechanobiology and optical detection of signal transduction ranging from optical micromanipulation-optical tweezers and scissors, advanced fluorescence techniques and optogenentics. In the current perspective paper, we concentrate our efforts on elucidating interesting measurements of forces, torques, positions, viscoelastic properties, and optogenetics inside and outside a cell attained when using structured light in combination with optical tweezers and scissors. We give perspective on the field concentrating on the use of structured light in imaging in combination with tweezers and scissors pointing out how novel developments in quantum imaging in combination with tweezers and scissors can bring to this fast growing field.

State primary standard of unit for torque GET 149-2023

The problems of metrological support for high-precision torque measuring instruments, which have a measurement range that includes torque values of less than 1.0 N·m, are considered. The areas of activity in which torque measurements are important are shown. The history of the development of the highest level reference base as an important link in the metrological support of torque measurements in the Russian Federation is described. Brief information is provided on the level of development of the reference base in this field of measurements abroad. As a result of the increase in the number of torque measuring instruments, the upper measurement limit of which is less than 1.0 N·m, there was a need to expand the measuring and calibration capabilities of the Russian Federation in this area, in particular, in the range of 0.1–1.0 N·m. The composition of the State primary standard for the unit of torque GET 149-2023 is given. The operating principles of the four reference installations included in GET 149-2023 and the structure of the reference are described. GET 149-2023 includes the created modern reference installation EU-250-2 for reproducing, storing and transmitting a unit of torque in the range of 0.1–200 N∙m. The results of studies of the reference installation EU-250-2 and the metrological characteristics of GET 149-2023 are presented.

A multifunctional reference torque standard machine

In response to the problem of using different single machines to achieve measurement and detection of existing torque instruments, this article introduces a multifunctional reference torque standard and proposes specific steps for torque measurement and detection. This standard machine can be used to detect various existing torque instruments and can solve the problem of using a single machine to achieve the detection of a certain type of torque equipment. After adopting this standard machine and its detection method, experimental data shows that the measurement of the torque transducer can meet the requirements of JJG995-2005 “Static Torque Measuring Machines” and the measurement of the reference torque wrench can meet the requirements of JJG1103-2014 “Reference torque wrench Verification Regulations”.

Optoelectronic Torque Measurement System Based on SAPSO-RBF Algorithm.

The torque is a significant indicator reflecting the comprehensive operational characteristics of a power system. Thus, accurate torque measurement plays a pivotal role in ensuring the safety and stability of the system. However, conventional torque measurement systems predominantly rely on strain gauges adhered to the shaft, often leading to reduced accuracy, poor repeatability, and non-traceability due to the influence of strain gauge adhesion. To tackle the challenge, this paper introduces a photoelectric torque measurement system. Quadrants of photoelectric sensors are employed to capture minute deformations induced by torque on the rotational axis, converting them into measurable voltage. Subsequently, the system employs the radial basis function neural network optimized by simulated annealing combined with particle swarm algorithm (SAPSO-RBF) to establish a correlation between measured torque values and standard references, thereby calibrating the measured values. Experimental results affirm the system's capability to accurately determine torque measurements and execute calibration, minimizing measurement errors to 0.92%.

Devising a technique for measuring torque of electric motors using machine vision

The object of research is the technique for measuring torques of electric motors. The main problem to be solved is the need to expand the range of informative parameters used in transmission torque converters of electric motors. This need arises from the design complications of placing the measuring devices directly on the motor shaft. As part of the study, a system was designed for determining the torques of electric motors, which combines the procedure for assessing the load on the shaft and software tools for visually determining the quantitative characteristics of such a load using machine vision. In order to acquire visual characteristics of the twisting of the shaft, a special coupling with an insert containing a liquid was designed. This coupling is able to change its shape in proportion to the load on electric motor shaft. The proposed visual control system, based on video information processing techniques, makes it possible to analyze changes in the shape of the coupling caused by the action of the torque. Features of the application of the proposed measurement technique are that there is no need to place electronic components of the measuring transducer directly on the shaft. Due to the specified features, the proposed procedure provides a solution to the problems of torque measurement in aggressive environments, which is of crucial importance for the efficiency of some specific production processes. Analysis of the visual characteristics of torque showed that the proposed approach could be applied in measuring transducers. At the same time, the results of testing the procedure confirmed that it requires the use of high-precision video recording equipment. This paves the way for the design of new, more modern, and reliable measurement systems that could be used in a wide range of industrial solutions

First-in-Human Pilot Study to Assess Methodology for Using a Mineral-Organic Bone Adhesive for Optimization of Primary Stability and Implant Success for Implants Glued into Immediate Extraction Sockets and Immediately Temporized: Pilot Study.

To assess the handling properties and clinical function of a new class of material, a so-called mineral-organic bone adhesive (Tetranite; TN), which as yet has no precedent in orthopedic or oral and maxillofacial surgery, for clinically unstable implants placed in immediate extraction sockets and immediately temporized in the anterior maxilla. A cohort of up to 15 patients requiring between one and four immediate dental implants placed into maxillary extraction sockets from canine to canine were eligible for inclusion. Implants had to be unstable with an insertion torque of < 15 Ncm. Implants were then stabilized using TN, which was allowed to set before reassessing stability using both torque and resonance frequency measurements. Implant stability quotients (ISQs) taken after TN setting were compared to ISQs taken prior to its application, and the implants had to demonstrate resistance to a forward torque of 20 Ncm to be considered stable. ISQs were monitored at 1 week and 1, 3, 7, and 12 months postplacement. In addition, peri-implant tissue health was monitored, adverse events were recorded, and implant success was determined at 1 year postplacement. Eleven patients received a total of 14 implants. Three out of the first six implants failed within 1 month (50%), and thus a protocol amendment was made to remove steps considered potentially destructive to the bonding process. As a result of these amendments, only one further failure was experienced for the next eight implants placed (12.5%). Mean ISQ data averaged for buccolingual and mesiodistal measurements demonstrated a baseline value before TN application of 59.1 Ncm (SD: ± 9.7; range: 40.5 to 73.0). After final setting of the TN, mean ISQ measured 71.9 Ncm (± 6.5; 56.0 to 80.0). At 3 months, just prior to restoration placement, mean ISQ measured 71.0 Ncm (± 6.6; 57.0 to 78.0). Thereafter, the mean ISQ continued to increase at both the 7- and 12-month follow-ups with scores of 78.9 (± 4.6; 72.0 to 84.5) and 80.3 (± 3.8; 74.5 to 85.0), respectively. The surviving 10 implants went on to be fully restored and remained in function beyond the end of the study period to yield a final success rate of 71.4%. The purpose of a first-in-human study is to demonstrate an extrapolation of preclinical data into the controlled human clinical arena. It is an opportunity to learn what does and does not translate well from experimental data. In that regard, the current pilot study can be deemed a complete success. The implant survival rate of 71.4%, while disappointing, should be considered in light of the protocol amendments identified, the user handling experience learned, and the opportunity to modify the material to better perform in the human patient, as all represent important lessons learned. The notable increase in ISQ sheds light on the nature by which the glue was substituted for bone to yield a stable implant by the end of the study period.

Development and Analysis of an On-Road Torque Measurement Device for Trucks

BackgroundRolling resistance and aerodynamic losses cause a significant part of a truck’s energy consumption. Therefore there is an interest from both vehicle manufacturers and regulators to measure these losses to understand, quantify and reduce the energy consumption of vehicles. On-road measurements are particularly interesting because it enables testing in various ambient conditions and road surfaces with vehicles in service.ObjectiveCommon driving loss measurement devices require unique instrumented measurement wheels, which hinders effective measurements of multiple tyre sets or measurements of vehicles in service. For this purpose, the objective is to develop a novel load-sensing device for measuring braking or driving torque.MethodsThe strength of the measurement device is calculated using finite element methods, and the output signal is simulated using virtual strain gauge simulations. In addition to the signal simulation, the device is calibrated using a torsional test rig.ResultsThe simulation results confirm that the device fulfils the strength requirements and is able to resolve low torque levels. The output signal is simulated for the novel cascaded multi-Wheatstone bridge using the strains extracted from the finite element analysis. The simulations and measurements show that the measurement signal is linear and not sensitive to other load directions. The device is tested on a truck, and the effort of mounting the device is comparable to a regular tyre change.ConclusionsA novel driving loss measurement device design is presented with an innovative positioning of strain gauges decoupling the parasitic loads from the driving loss measurements. The design allows on-road testing using conventional wheels without requiring special measurement wheels or instrumentation of drive shafts, enabling more affordable and accurate measurements.