SOREM, the historical leader in mechanical transmission, founded in 1953, is an authentic global benchmark in the construction of universal double-couplings that, once completed, are ready to be assembled and implemented on tractor axles, earthmoving machines, forklifts, airport’s conveyor belts, trucks, and any other off-road vehicle.
To ensure maximum efficiency, SOREM has implemented a constant and continuous update of its systems over time, carried out internally with overhaul and retrofit procedures and with external collaborations.
Thanks to a consolidated know-how over decades of demanding industrial applications, the company built its success mostly on mechanical robustness.
However, with the introduction of Industry 4.0, the subsequent 5.0 transition, and the combined demand from customers for increasingly optimized process tolerances, the 70 years know-how must be constantly supported by measurement solutions that demonstrate quality.
It is therefore obvious that, despite decades of successful testing, the outdated test bench is no longer able to meet neither the certification standards required by international markets, nor the process and measurement tolerances demanded by customers.
Documenting and tracking the robustness of SOREM’s universal double-couplings, according to the latest requirements becomes the goal to be achieved.
In other words, this means documenting and validating the robustness, both of the test bench and of the universal double-couplings that SOREM’s customers have taken for granted for decades.
This allows having a system/test bench for universal double-couplings, that not only mechanically resists failures but also describes the entire dynamic wear process of the coupling throughout its service life.
SOREM’s test bench
Regarding the test bench upgrade and the description of the dynamic wear process, a measurement solution that combines the mechanical robustness of the universal double-coupling with the accuracy of the torque sensor, was the way to go.
Among the potential suppliers, collaborating with acquati group, a product and service division of burster Italia, has proved to be the best solution.
burster Italia, a company who has been part of the torque-angle and force-displacement process control sector for over 30 years, developed the customer’s needs and goals and confirmed that torque sensors are the excellent components that allow monitoring the breaking torque and torsional stresses during extreme load cycles, essentials to validate the coupling’s operational life.
Torque sensor model 8627-6020 burster
The torque reaction sensor model 8627-6020, FS 20 kNm, has allowed, during the design phase, to have:
- mechanical flange-flange interface, facilitating the positioning of the Sapit flex coupling and the design of the whole kinematic chain
- optimized length along the longitudinal axis (axis of rotation), minimizing the overall measurement chain;
- central through hole to facilitate both electrical connections and utility connections;
- optimized torsional stiffness to achieve high bandwidth;
- enhanced accuracy and robustness for process control.
This measurement solution (reaction torque sensor) together with the angular measurement via incremental encoder model BAUMER BDK16.05A1024-5-4, allows to have two signals (Nm and degrees) with optimized bandwidth for process control.
DIGIFORCE 9307 burster
The instrument that completes the measurement solution is DIGIFORCE 9307 burster, the process controller which, by connecting the torque signal (Nm) and the angle signal (degrees), describes and allows to evaluate the dynamic wear process with a 10kHz bandwidth thanks to the resulting curve.
SOREM was therefore able to map the performance of universal double-couplings in high frequency, allowing to discriminate every minimum torsional drift, transforming the experience of more than seventy years into graphs, parameters and process tolerances.
In other words, x/y controller DIGIFORCE 9307 burster allows you to monitor, through the process tolerances defined during the analysis phase and a high bandwidth, the complete dynamic of each individual rotation, identifying variations in high frequency.
This identification led to the destructive tests being stopped at the exact critical point, protecting the test bench components such as the torque sensor and the couplings.
Testing times are also reduced. Below you can find hardening process verification testing (before and after induction hardening). 10 cycles/minute. The individual tests are completely tracked thanks to the Digicontrol software connected to the DIGIFORCE 9307 controller.
Single test report (torque Nm – degree angle graph included) before induction hardening
Single test report (torque Nm – degree angle graph included) after induction hardening
Through the tests reported above via measurement protocol, it is shown that induction hardening leads to a clear increase of the coupling’s stiffness. (reduced hysteresis and reduced deflection angle to reach same torque value).
The combination of the manufacturer’s historical expertise (SOREM) and the measurement technology (burster Italia – acquati group) has led to:
- complete certification. High-resolution data allow the complete traceability of each batch produced, ensuring to the final customer that the coupling’s operating life was certified with extremely precise safety margins.
- having access to a significant amount of data, fully traced, making in-depth mathematical analyses possible: from the average peak value to the least squares estimate.
- SOREM demonstrating that its couplings maintain constant torque for millions of cycles by providing objective evidence of both its know-how and historical design.
- high-frequency data that leave room to improvements, allowing the company to further develop a product that is already excellent.
- competitive advantage both for SOREM and burster Italia. The ability to provide extremely detailed end-of-life reports has solidified the reputation of both companies not only as component suppliers but as technology partners as well.