Rapid Deployment Torque Telemetry System

KillerBug®

Wireless

Low Noise

Low Power

High Resolution

Install and stream data in under

5 minutes
Wireless Torque Measurement KillerBug

Transmission Dynamics proudly presents the KillerBug® – Torque Telemetry system designed to measure input shaft torque (and bending) on industrial drive systems. Suited for various applications, including (but not limited to) wind farm profiling, the system can effectively capture transient events like torque reversals that damage bearings and gearboxes.

Wireless Torque Measurement Infographic

KillerBug® Wireless Torque Measurement Example Applications

Validation of load conditions

Troubleshooting and investigation

KillerBug Torque Telemetry Example

Detection of transient events

Fatigue life evaluations

KillerBug Example Installations
Torque reversals graph

Due to the varying dynamic response of mechanical systems, direct measurements of input torque are vitally important to better understand in-service loading.

In wind systems, torque transients can occur for a number of reasons, including mis-synchronisation of turbines onto the grid, emergency brake events, or interactions with the control system during mode changes.

Torque reversals such as the one shown on the left-hand side are not uncommon. Such torque reversals result in the shaft suddenly loading of misaligned bearings which typically operate in the unloaded zone. This results in higher than permissible edge contact stresses and ultimately can result in bearing failures.

Rapidly reversing bearing load zones

Rapid torque reversing graph

Real measurements of bearing skew in the bearing unloaded zone

Want to understand torque reversals further?  Click on our article from Gear Solutions.

The article discusses the importance of understanding and preventing in-service failures in wind turbine gearboxes. With the growth of wind energy and the deployment of larger turbines, there is an increased focus on reliability and cost-effective operation. The cost of repairs, downtime, and maintenance becomes significant, especially in offshore wind farms. To address these challenges, effective condition monitoring and early maintenance indicators are crucial. The article highlights the need for a fundamental understanding of in-service failures and the development of experimental and analytical techniques.

Most wind turbine generators consist of various components, including the rotor, hub, input shaft, gearbox, disc brake, and generator. The gearbox plays a crucial role in transferring torque from the slowly rotating input shaft to a high-speed output for the generator. The article mentions that even gearboxes designed within accepted standards and operating within theoretical design limits can still experience failures in wind turbine installations. The unique load patterns in wind turbine generators contribute to these failures, and a complete understanding of the causes is yet to be achieved.

Click on the image to read our article.

Wireless Torque Measurement KillerBug

Key Features of KillerBug®

Versatile Deployment

Designed for torsional and bending stress measurements.

Ready-to-Deploy

The KillerBug transmitter features wireless torque measurement data transmission, an internal battery, and comes prewired to a torque gauge, bending gauge, and temperature sensor.

Extended Battery Life

Continuous operation for 12 to 32 days, depending on sampling rate and operational temperatures. Sleep mode extends life to up to 5 years.

Battery Saving Mode

Simply power off the receiver, and the wireless torque measurement transmitter will enter a low-power sleep mode.

Wide Operating Temperatures

Standard range from -20⁰C to +80⁰C, with extended versions available.

Customisable Sampling Rate

Select from 104 Hz, 208 Hz, 416 Hz, or 833 Hz depending on your requirements.

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Killer Bug

Wireless data streaming with ~20m range (depending on the environment)

*Patent pending technology

The Benefits of KillerBug®

Load Profiling

Enables the detection of drive-line torque and transient events such as torque reversals which can lead to early bearing failures.

Rapid Installation

The system is designed to be installed and transmitting data within 5-minutes by non-skilled personnel.

Space-efficient Design

With dimensions of Ø40 mm x 20 mm, KillerBug® fits into limited spaces.

Inclusive Kit

Comes pre-packed with essential installation items.

The Receiver

Wireless Torque Measurement Receiver

The signal is streamed live from the transmitter to the receiver. The SMB connector provides a 0-5V output or 4-20 mA output for interfacing with an external data acquisition system.

– or –

Alternatively, the receiver can be connected to a laptop via USB-C, enabling recording of data directly onto a hard drive.

Installation Kit

KillerBug Torque Telemetry Box

Our installation kit includes:

The KillerBug® Torque Telemetry Installation Process

How quick and simple KillerBug® installation is

1. Abrade and clean the target surface.
2. Apply a thin layer of adhesive catalyst on the shaft surface. Add a drop of cyanoacrylate adhesive onto the strain gauge and a couple of drops on the transmitter housing edge.
3. Place the KillerBug® transmitter over the marked location. Its integrated magnets should hold the transmitter onto the surface, allowing the foam supporting the strain gauge to create the right pre-load. For shafts with speeds above 100 RPM or on diameters 0.5m, consider using structural adhesive or other fastening methods.
4. Watch the data flow.

Require higher sampling rates?

…or have a more demanding industrial application?

The KillerBug® – Torque Telemetry System is your answer to efficient torque measurements in many rotating machinery applications. Its compact design, extended battery life, and easy installation make it a prime choice for rapid-deployment, validation or troubleshooting projects; enabling the validation of loading conditions, detection of transient events, and evaluation of fatigue life.

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