Rotating torque sensors

Rotating Torque Sensors

Rotating torque sensors (also known as rotational torque or torsion sensors) are used for —precise measurement of torque directly on rotating shafts and components - such as in drivetrains, motor and gearbox test benches, or in production and quality assurance processes. They provide reliable measurement data when torque needs to be captured under real operating conditions, from static loads to dynamic load changes.

At Althen, you will find rotating torque sensors in various designs and with different measurement principles, tailored to your mechanical installation and measurement concept. This enables reliable implementation of measurement tasks in mechanical engineering, automotive development, e-mobility, as well as in test benches and end-of-line testing.

The Right Rotating Torque Sensor for Your Application

Rotating solutions are typically chosen when:

• Torque must be measured under rotation (realistic measurement on rotating systems)
• High dynamics are required (load changes, acceleration/braking processes, transient operation)
• A robust and integrable measurement system is needed (suitable mechanics, signal conditioning, optional interfaces)

Depending on your application, we also support you in selecting the appropriate measurement chain (e.g., signal transmission, amplification, data acquisition), ensuring that your measurement results are not only accurate but also stable and reproducible within the overall system.

What to Consider When Selecting a Rotating Torque Sensor

For reliable system design, the following factors are typically crucial:

• Measurement range / nominal torque
  Including overload capacity and appropriate safety margins.
• Speed range and dynamic behavior
  Consider the required performance under dynamic loads such as acceleration, braking, and load changes.
• Mechanical integration
  Shaft connections, flanges, and available installation space must match the application.
• Environmental conditions
  Factors such as temperature, dust, humidity, and possible shock or vibration loads should be taken into account.
• Output signal & interfaces
  Analog or digital outputs must be compatible with your test bench, PLC, or data acquisition system.
• Calibration & traceability
  Important for quality assurance, compliance with standards, and audit requirements.

Typical Applications of Rotating Torque Sensors

The main applications for rotating torque sensors are found wherever torque needs to be measured directly on a rotating shaft under real load conditions:

• Test benches for engines, gearboxes & drivetrains
  Development, validation, efficiency testing, and endurance testing
• E-mobility / electric drives
  Electric motors, inverter setups, eAxles, energy recuperation, torque ripple analysis
• Quality assurance & end-of-line (EOL) testing
  Functional testing, friction torque and breakaway torque measurement, comparison with reference values
• Mechanical engineering & production systems
  Drive monitoring, process stability, wear and condition monitoring
• Tool and spindle testing (e.g., screwdriving systems, milling/drilling spindles)
  Torque progression, control quality, overload peaks
• Pumps, compressors, and fans
  Power consumption, efficiency, and performance curve measurements
• Wind energy & rotor systems
  Torque and power analysis in drivetrains (test bench and field testing)
• Robotics & automation
  Drive and axis characterization, control system testing, load profiling
• Research & university laboratories
  Model validation, tribology/friction torque analysis, material and component testing