MATEC Web of Conferences 220, 0 3006 (2018) https://doi.org/10.

1051/matecconf/201822003006
ICMSC 2018

Measuring the Torque of a Combustion Engine.

1 1
Josef Popelka , Celestýn Scholz
1
technical University of Liberec, Studentská 1402/2, Liberec, Czech Republic,

Abstract. This paper deals with the measurement of torque using a designed torque sensor. To determine the
indicated engine parameters, the torque along with the torque in the combustion space of the individual cylinders are
measured. I worked on the measured values to determine the dependence of the torque moments on the engine load.
The obtained data was used to assess the possible use for further measurements.

1 Introduction RPMs of electric machine. Using of this method is not

very common because measure is influenced by
Over the past few decades, the requirements and criteria significant error of measurement a lot of physical quality.
that must be met by car manufacturers are constantly If we improve this measure by adding a torque sensor we
increasing. Legislators have considerably contributed to can use electric generator to put load on the engine which
this by directly influencing production in the individual is proper and common use alternative.
sectors through the creation of various emission
regulations and standards. The other side of the coin is
2.1.2 Torque measure with piezoelectric pressure
the price, which is of interest to the end consumer. In
sensor.
addition to price, potential customers are interested in the
parameters of the vehicle, such as consumption and the This method is an exclusive solution by AVL Company
quantity of pollutants produced. Of course, these two and it is mostly used for the special measuring powertrain
parameters are directly proportional to the performance stands or engine dynamometers. Method measures
parameters and, therefore, a reasonable compromise pressure directly with pressure sensors inside the
needs to be found. Car makers, of course, are searching combustion chamber. If we put normal force into
for more ways of achieving better performance with piezoelectric sensor’s silicon plate it generates electric
lower or equal consumption. As a way of saving power or charge which is direct proportional to force. We need a
fuel, a direct option is to reduce internal engine losses. In characteristic indicated pressure depended on crank shaft
order to understand this issue and reduce losses as much angle to get characteristic of indicated torque. We use
as possible, there is no suitable measurement method at incremental sensor connected to crankshaft to
present. determinate its angle. To get effective torque we need to
know friction moment and inertia moment of the engine.
2 Basic methods for measuring torque [3], [4]

Torque measuring methods are divided into two basic 2.1.3 Torque determination from inertia moment.
groups:
x Indirect torque measure We can determinate engine’s power, respectively torque
x Direct torque measure (Measure using torque or by measuring RMPs and time needed to spin body of
force sensor) known inertia moment. It is the simplest measuring
x Special way (Combination) technique and nowadays it is just used at amateur
conditions because of great error in measurement. It
cannot be used during long-term measure. It can be used
2.1 Indirect torque measure as comparison method with some success.

2.1.1. Torque measure with electric machine. 2.2 Direct torque measure (Measure using
In case when combustion engine is connected to electric torque or force sensor)
generator is the possibility to measure power, Measure using torque sensors is mostly used of its
respectively torque by measuring of voltage, current and accuracy and repeatability. Principe is based on the direct

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0
(http://creativecommons.org/licenses/by/4.0/).
MATEC Web of Conferences 220, 0 3006 (2018) https://doi.org/10.1051/matecconf/201822003006
ICMSC 2018

torque measure. Differences between each type of sensor 2.2.5 Capacitive sensor.
are in physical method used for torque measure.
Most of torque sensor is using shaft as a deformation Capacitive sensor is made from two tooth shaped
element. Differences between these sensors are that some electrodes which are bonded into a shaft with enough
uses own shaft and others use shaft from measured device. tooth space. Shaft deformation causes decreasing of the
Second option can by inaccurate sometimes. [1], [5], [6] tooth space by electrode rotation which leads into change
Torque sensors types: of capacitive. One of electrodes has to be perfectly
• Resistive sensor isolated from the shaft otherwise capacity will not change.
• Induction sensor [1], [5], [6]
• Capacitive sensor
2.3 Measuring torque by measuring the force on
2.2.1 Resistive sensors a known arm

Resistive sensors are most widespread with simply This is a sophisticated method based on measuring the
construction. Measure is based on deformation of reaction in the storage of the measured unit. The method
measuring element which is shaft in most cases. Sensors s commonly used, for example, with older types of
can be divided into two groups. First one uses own shafts dynamometers. An advantage is the simplicity of the
putted into measuring track. Second one uses shaft of measuring device, and a disadvantage is measuring errors
measured device. [1], [5], [6] affected by the storage of the measured unit. [1]

2.2.2 Sensor with resistive potentiometer. 3 Design of measuring devices for

monitoring engine torque
Its function is based on angle deviation of measured shaft.
Sensor requires significant deformations of measured From the principle of torque measurement, we offer two
element. Sensor electronic transforms a resistivity into solutions for obtaining the torque directly from the engine.
electric signal that is directly proportional by sensor’s The simplest solution is to use a suitable cylindrical part,
deformation. [1], [5], [6] such as a flywheel, to which strain gauges are attached.
This method can be used to measure the surface tension
2.2.3 Sensor with resistive tensometer. on the selected part in order to determine the torque.
Unfortunately, this method has several pitfalls. Probably
Sensor principle is based on the measure of shear stress the largest one is the signal transmission from the rotating
with tensometer. Tensometer is very often used sensor part. Another is the very tight space for attaching the
because of no requirement of measuring element. strain gauges and the harsh environment between the
Unfortunately is necessary to solve signal transmission engine and the gearbox, mainly in terms of temperature.
from rotating part. Measured element is mostly cylinder The last important factor is the lack of experience with
shape part with several glued tensometer by 45° angle to attaching and subsequently using the strain gauges. The
axis of rotation. This assemble creates so called second solution involves the use of industrially-
tensometric bridge. [1], [5], [6] manufactured measuring elements. In our case, the
measuring flange is the most suitable. A significant
disadvantage of this solution is the installation
dimensions of the flange, but we have a functional and
tested measuring element that can be used. [4]

Figure 1. Schema of Tensometric Bridge [1]

2.2.4 Induction sensor.

Induction sensor got small air cavity. Angle

deviation of shaft is dependable on air cavity
change. Sensor’s coil is placed on the stator part, Figure 2. Kistler 4504B measuring flange [2]
which also solve signal transmission from
rotating shaft.

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MATEC Web of Conferences 220, 0 3006 (2018) https://doi.org/10.1051/matecconf/201822003006
ICMSC 2018

Figure 4. Overall view of the measurement elements mounted

Figure 3. Model of measuring device [6] on the engine. [3]

3.1 Sensor installation

In order to define the space required for installing the
measuring flange, we selected a very simple method
using composite steel sheet fragments. This is a test
design so it is possible to consider a case made from
aluminium alloy in the future. The measuring flange is
designed by the manufacturer to be subjected to torsional
stress only, any other stresses are not permitted.
Therefore, the whole system is mounted inside a ball
bearing, which captures the axial forces from the clutch
disengagement and possible radial forces from the
bending stress of the system due to its own weight. [5]
Measuring device is designed that by adding another
rotating mass into crank shaft it follows that is necessary
to remove some material from it for gain get acceptable
inertia moment.
Table 1. Moment of inertia. Figure 5. Overall view of the measurement elements mounted
on the engine. [3]
Moment of Weight
inertia m [Kg]
I [Kg*m2] 4 Experiment
flange of crank shaft 0.00452 1.135
sensor 0.01164 1.100 The experimental work was carried out on a supercharged
flange of flying wheel 0.01106 2.850 EA 211 1, 4 TSI engine fitted with a sensor for measuring
bearing 0.00707 0.910 the pressure inside the cylinders, and the torque, which is
original flying wheel 0.073 6.521 measured directly on the crankshaft. The development of
adjusting flying wheel 0.03871 4.157 the individual variables was displayed and processed
using an AVL Indicom 619 signalling device. Along with
To put measuring element into measuring track, the above engine parameters, the courses of the signals on
between engine and transmission, is necessary to create the ignition modules and the fuel injectors were measured
the case enough which will be a part of the engine. For using the clamp probes. With an engine set up in this way,
quite simple manufacture, case is made if you like it is possible to obtain an overview of all of the required
assembled from several pieces of plasma cut metal sheet. parameters.
This is just first version of case but in future in could be The tested engine was mounted on the test bed with
made by aluminum casting. an ASD 235 electric asynchronous dynamometer. The
The construction of torque sensor doesn’t allow any required and measured parameters are monitored and
other stress except torsion stress. Therefore is necessary fully controlled by a desktop computer. To ensure safe
to put bearing into assembly which avoids bending stress operation of the engine, other engine parameters such as
and axial stress caused by hydraulic clutch. This type of temperature and pressure of running fluids were also
case construction brings just torque stress on torque monitored.
sensor along with zero axial stress.

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MATEC Web of Conferences 220, 0 3006 (2018) https://doi.org/10.1051/matecconf/201822003006
ICMSC 2018

Table 2. Construction parameters of engine.

Type of engine EA 211, 2xOHC

Bore x stroke 74.5x 80 mm
No. of valves 4
Type of fuel Direct fuel injection with
supercharging
Compression ratio 10.5:1
Volume 1398 ccm
Maximum power output 103 kW
Maximum torque 250 Nm

During the measurement it was necessary to take into

account the torque sensor, which is designed to be used
up to 4,000 rpm. The engine already has a high torque at
1,000 rpm due to its construction and supercharging.
Figure 3. The rate of Loss moment in relation to the engine
With respect to the above facts, the experiment was revolutions
performed at revolutions of between 1,000 rpm and 3,500
rpm. In terms of torque, it had to be ensured that the
maximum torque the sensor is designed for is not
exceeded, which in this case was 1,000 Nm. It may seem
that if the maximum torque of the sensor is 4 times
greater than the engine torque, then the safety of the
measurement is considerable, but the opposite is true. The
maximum engine torque is only an effective value, the
peak torque is many times greater. Therefore, a maximum
torque of 200 Nm was chosen during the experiment.
Table 3. Operating engine speed during experiment.

Measurement of engine revolutions [RPM]

1000 1250 1500 1750 2000 2250
2500 2750 3000 3250 3500
Figure 4. The rate of Loss moment in relation to the engine
revolutions
Table 4. Engine load per operating engine speed.

Measurement of engine load [Nm] 6 Conclusion

5 10 25 50 75 100 125 150 175 200 During the experimental work, combustion pressures
were measured at different revolutions and with different
The basic assumption of the whole measurement was engine loads. The engine torque was measured in two
verification of the function of the designed torque sensor ways. Firstly, by a torque sensor, which is part of the
and the measurement of the effective and indicated dynamometer? Secondly by measuring the torque directly
parameters of the engine for the detection of the torque of on the engine’s crankshaft. During the measurements,
the engine and the influence of the load on the both methods showed quite similar results. The problem
measurement of the torque. is that data is offset due to possible inappropriate setting
Figure 3 shows the course of the loss moment of the measuring flange. Further research will be
obtained from the effective torque measured using an focussed on clarifying this phenomenon. After clarifying
asynchronous dynamometer. Figure 4 shows the course the difference in the measured values, it will be possible
of the loss moment obtained by measuring the torque to evaluate the overall accuracy of the measurement
directly on the crankshaft method. Despite this phenomenon, the method of
measuring the torque directly on the crankshaft was
found to be very accurate and can be used for further
5 Results experimental work.
From the measured data, it was possible to plot the course
of the torque depending on the engine load. The Acknowledgements
following figures display data from both methods of
measurement. The results of this project LO1201 were obtained through
the financial support of the Ministry of Education, Youth
and Sports in the framework of the targeted support of the
“National Programme for Sustainability I” and the

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MATEC Web of Conferences 220, 0 3006 (2018) https://doi.org/10.1051/matecconf/201822003006
ICMSC 2018

OPR&DI project Centre for Nanomaterials, Advanced 3. Popelka Josef; Návrh zařízení pro analýzu průběhu
Technologies and Innovation CZ.1.05/2.1.00/01.0005 momentu mezi motorem a převodovým ústrojím
automobilu, Závěrečná zpráva SGS; Liberec 2016
4. Vinklář Jiří; semestrální práce, Projekt II, Liberec,
References 2010
1. Ďado Stanislav, Kreidl Marcel; SENZORY a měřicí 5. Popelka Josef; Metody měření točivého momentu
obvody, Praha 1996 spalovacích motorů, Harrachov 2015
2. www.Kistler.com 6. Popelka, Mikulanin, Scholz ; Construction of the
measuring device for analyzing the torque of internal
combustion engine, Saint Petersburg 2015

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0
(http://creativecommons.org/licenses/by/4.0/). 5