The document discusses a problem with a machine's braking system not filling with brake oil. Potential reasons are investigated, and the major cause is found to be improper torque of nuts during assembly. To address this, a strain gauge setup was proposed to measure torque, but deemed unsuitable due to cost, bulkiness, and maintenance needs. An alternative sensor called Torqstar is presented, using magneto-elastic materials in a compact, low-cost design, but cannot currently be used due to requiring wireless approval processes taking 6 months.

2. Problem statement :
 There is a problem in braking system, because of
which the machine is not filling the brake oil.

3. Possible reasons :
1. Torque not ok.
2. Leakage problem.
3. Problem in TMC.
4. Brake hose dust accumulation.
5. Brake oil reservoir not connected properly.
6. Brake drum quality not assured.

4. Problem analysis :
 After a thorough analysis of the braking system, the
major cause out of the mentioned reasons was found
to be torque not ok. Or in other terms ‘missed
torque’
 As human intervention is found more in this case,
there is possibility that the worker might have missed
to torque all the nuts, as there are 28 nuts that need
to be torque, with a pre-set value of 18 Nm.

5.  As mentioned, the major persuading reason for
the failure in the braking system is, torque not ok
problem.
 So there needs to be an counter measure taken to
avoid this problem and help increase the
production.
 Other causes are also addressed and the solution
is found within the plant itself.

6. Solution :
MEASUREMENT OF TORQUE USING ‘STRAIN
GAUGE’.
 THE SETUP:
 Torque Indicator is a strain gauge signal conditioner and
amplifier used to measure Torque due to load applied on
the Torque Cell.
 The strain gauge is bonded on the Specimen and is
connected in the form of Whetstones Bridge. A pan and
weights up to 1Kg with fulcrum arm of 1m length is
provided to load the Torque Cell. Torque measuring setup
is a complete system which can be used to conduct
measurement of load applied on the Torque cell. The
Torque indicator is provided with zero balancing facility
through adjustable potentiometer. The system operates on
230V Ac supply.

7. Specifications of torque indicator
 TORQUE INDICATOR
 DISPLAY RANGE : 3.5 digit RED LED display of 200 mV FSD to read up to +/-1999
counts.
 ACCURACY : +/-0.5% of FSD
 RESOLUTION : +/- 0.01 Kg-MS
 BRIDGE EXCITATION : 10V DC
 CALIBRATION : Directly loading sensor at 1meter arm length 1.00 Kg-m
 POWER : 230 V +/- 10% at 50Hz. with perfect grounding.

8. Some of the reasons for not opting the
Solution :
 Although strain gauge torque transducers provide
high accuracy
 It is not Applicable because of-
1. Their high cost.
2. Bulkiness.
3. require high maintenance levels.
 making them unsuitable for mass integration into
manufacturing systems.

9. Alternative :
The Torqstar Torque Sensor
 The new Torqstar sensors meet the challenges for sensors
to be used in manufacturing environments and can now be
designed directly into production equipment.
 They cost up to 60% less than comparable strain gauge
methods. The accuracy of the new transducers is within
0.5% of full scale comparing favorably with strain gauge
units costing almost five times as much, and they offer a
compact size and rugged construction.

11. About the sensor :
The sensor is made up of two main components:
1. A stainless steel shaft , dimensioned for the appropriate
torque,
2. And a second metal ring , which fits tightly on the shaft.
Although the ring appears to be normal steel, it is
actually a special titanium-nickel material
which has the property of being magneto-elastic.

12. WHAT ARE MAGNETO-ELASTIC
MATERIALS.?
 Magneto-elastic materials are commonly known as pseudo
magnets. When at rest, they produce no external
magnetic fields, but as soon as their form experiences a
change in shape through applied stress, their magnetic
characteristics change to give a field whose strength is
directly proportional to the applied stress.

13. Reason for not using the sensor :
1. The main reason is that the sensor is wireless and is
monitored by transducer, so for any wireless application
within industry there must be approval by the government
which will take around 6 month for its approval.
 Hence even though the Torqstar torque sensor is compact
, low cost and ready to use material it cannot be used as
for now.