A Novel Variable Stiffness Torque Sensor with Adjustable Resolution

In rotating machinery, the demands for torque sensor resolution and range in various torque measurements are becoming increasingly stringent. This paper presents a novel variable stiffness torque sensor designed to meet the demands for high resolution or a large range under varying measurement conditions. Unlike traditional strain gauge-based torque sensors, this sensor combines the advantages of torsion springs and magnetorheological fluid (MRF) to achieve dynamic adjustments in both resolution and range. Specifically, the stiffness of the elastic element is adjusted by altering the shear stress of the MRF via an applied magnetic field while simultaneously harnessing the high sensitivity of the torsion spring. The stiffness model is established and validated for accuracy through finite element analysis. A screw modulation-based angle measurement method is proposed for the first time, offering high non-contact angle measurement accuracy and resolving eccentricity issues. The performance of the sensor prototype is evaluated using a self-developed power-closed torque test bench. The experimental results demonstrate that the sensor exhibits excellent linearity, hysteresis, and repeatability while effectively achieving dynamic continuous adjustment of resolution and range.