Applying our in-depth knowledge in the area of magnetomechanics to the monitoring and control of a variety of machinery used across industries ranging from motorsport to aerospace to energy, MagCanica offers a number of products addressing many challenging real-world applications. MagCanica's primary product is its naturally wireless torque sensor system. While most of the MagCanica product line consists of a variety of torque sensor systems and associated signal conditioning electronics, we are also provide rate-of-change of torque (ROC) sensor systems as well as non-destructive evaluation systems based on the Drag Force Method (DFM).
One of the primary benefits of the MagCanica torque sensor system is the fact that its compact packaging and high frequency response favor its placement at multiple locations in a powertrain. In particular the sensor can be placed on each driveshaft (half-shaft) and also on the clutch shaft (transmission input shaft). Doing so allows our motorsport clients to fully monitor and/or control their powertrain at the most specific level. MagCanica's typical 3-channel system, which measures torque on the right driveshaft, the left driveshaft, and the clutch shaft, offers a wealth of information about the performance of a high performance motorsport transmission. The signal flow diagram for each channel is shown below:
Signal Flow Diagram for MagCanica's motorsport torque sensor system.
Upper plot: during the course of one full lap, clutch shaft torque as measured by the MagCanica torque sensor system (blue).Lower plot: during the course of one full lap, a graph of the right driveshaft torque (green) and left driveshaft torque (red) as measured by the MagCanica torque sensor system
View of the MagCanica driveshaft torque sensor
system mounted on a Formula 1 driveshaft (half-shaft).
The MagCanica driveshaft torque sensor system is designed to accurately measure transmission output torque, or wheel torque. The system is the most lightweight, compact and accurate available on the market. Typical nominal torque ranges are approximately 2,500Nm, with rotational speeds as high as 3,000 RPM. The MagCanica driveshaft torque sensor system is used at track tests and races, primarily to optimize differential performance. Thanks to its non-invasive packaging and the fact that it can be mounted radially (i.e. it does not need to be mounted axially from one end of the shaft), it can be easily integrated into a typical final drive assembly, even with shafts having integrated tripod joints.
The MagCanica driveshaft torque sensor system is particularly useful for the following:
- Differential map tuning at the track
- Launch control
- Traction control and/or torque-based engine control
- Closed-loop torque control of the differential in real time
- Evaluating true vehicle aerodynamic efficiency
- The effectiveness of aerodynamic setup changes (eg. coast-down testing, straight-line testing)
- Output for gearbox efficiency analysis
Clutch Shaft (Transmission Input Shaft) Torque Sensor System
Front view of the MagCanica clutch shaft torque
sensor system installed on a Formula 1 gearbox.
The MagCanica clutch shaft torque sensor system is designed to accurately measure engine output torque, or transmission input torque. It is effectively an in-vehicle dynamometer. The system is the most lightweight, compact and accurate available on the market. Typical nominal torque ranges are approximately 300Nm, with rotational speeds are as high 20,000 RPM. The MagCanica clutch shaft torque sensor system is used at track tests and races to optimize engine and gearbox performance. Its strong reliability and robustness allow it to survive the harsh clutch environment, characterized by very high temperatures and vibration levels. View of the MagCanica driveshaft torque sensor system mounted on a Formula 1 driveshaft (half-shaft).
The MagCanica clutch shaft torque sensor system is particularly useful for the following:
- Actual horsepower determination at the track
- On-board engine diagnostics (eg. misfire, gradual power loss due to wear)
- A valuable tool for engine calibration and driveability tuning
- Clutch characterization and control
- Launch control
- Traction control, torque-based engine control
- Input to gearbox efficiency analysis
For motorsport clients specifically interested in the maximum degree of optimization of their clutch torque transfer characteristics and gear shift strategy, MagCanica offers torque sensor systems that can be run inside the gearbox, fully immersed in oil. Typically these systems are run on the secondary shaft, or mainshaft, in addition to the standard 3-channel system in order to monitor the amplitude and chronometrics of torque transfer from the clutch shaft to the secondary shaft, and in turn from the secondary shaft to the driveshafts.
MagCanica is actively pursuing the development of torque sensor systems for the KERS application in Formula 1, expected to become a standard item during the 2009 racing season. Whether it be a flywheel or electric storage system, and whether it be gearbox-mounted or engine-mounted, MagCanica is leveraging its many years of F1 torque sensor engineering experience to design the lightest, most compact, most accurate F1 KERS torque sensor systems available on the market. In particular, the extensive testing carried out to date has demonstrated the MagCanica KERS torque sensor's immunity to the high magnetic fields emanated by a typical KERS Motor-Generator Units (MGU). MagCanica is working actively with several F1 teams as well as KERS system developers to be at the forefront of this exciting new application.
In addition to its in-vehicle torque sensor systems, MagCanica provides a wide range of customized solutions for dynamometer applications as follows:
- Single-cylinder (mono-cylinder) engine dynos
- V6, V8, or V10 full engine dynos
- Full powertrain, or power-pack, dynos (engine + gearbox + differential)
- Transmission dynos (gearbox + differential)
- Differential dynos (differential only)
- KERS Motor Generator Unit dynos
Thanks to its non-invasive, dynamic mode of torque measurement (i.e. it is not a reaction torque sensor requiring a discrete interruption of the dyno torque flow as most conventional torque sensors), the MagCanica dyno torque sensor can be installed much closer to the prime driver than is customary. This provides the key benefit of detection of transient torque peaks of significantly higher amplitude than those normally recorded with conventional dyno torque sensors such as telemetric strain gauges.
Captured during a transition from idle to part-open-throttle to idle, a plot of MagCanica Torque Sensor System Output ("Torque MC") vs. Engine Dynamometer Torque Sensor System Output ("Torque Dyno") for both instantaneous response, and average ("Filt") response, during a Formula 1 engine dyno test. Notice the excellent matching of both signals for average response, but the significant difference in the unfiltered values showing the superior frequency response of the MagCanica torque sensor system.
Signal-Conditioning Electronics for Torque Sensor System
MagCanica provides various options for signal-conditioning electronics associated with operation of its torque sensor systems. We offer 1-channel, 2-channel, and 3-channel signal conditioning modules housed in discrete packages. Additionally, we offer 1-channel solutions that are more closely integrated with the sensor housing assembly, either within the housing itself (integrated signal conditioning electronics) or within the sensor loom or harness (inline signal conditioning electronics).
"GEN II" 3-Channel Signal Conditioning Module
"GEN III" 3-Channel Signal Conditioning Module
"GEN IV" 1-Channel Signal Conditioning Module
"GEN IV" Inline Signal Conditioning Electronics
For applications such as such as clutch shafts or KERS shafts, in which the local shaft environment involves temperatures exceeding 125°C, the signal-conditioning electronics can be integrated into the wiring loom at a set distance (as long as 2.5m if necessary) from the sensor housing.