Torque value monitoring method and device for prefabricated torque wrench

Abstract

The invention relates to a torque value monitoring method and device for a prefabricated torque wrench. The device comprises a workbench, a driving assembly, a moving assembly, a height adjusting assembly, a fixing assembly, a torque sensor and an angle sensor. The driving assembly controls the moving assembly to move left and right and is provided with the height adjusting assembly. The fixing assembly is used for installing the torque wrench body. The angle sensor is detachably installed on the torque wrench body through the fixing ring. According to the method, a tested torque wrench is specifically connected with a test board, a torque instrument and a computer are matched to collect test data, software analyzes the data, a secondary unloading point is considered from the two dimensions of elapsed time and a slip angle, the influence degree of secondary unloading on a torque measurement value is judged, and the test accuracy is improved. And the performance of the torque wrench is evaluated, and use suggestions are given. The performance of the torque wrench can be comprehensively and accurately evaluated, manual intervention is reduced, and the test accuracy and reliability are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of torque wrench testing, in particular to a method and a device for monitoring the torque value of a prefabricated torque wrench. Background Art

[0002] In industrial production and equipment maintenance, torque wrenches are precision tightening tools, and the accuracy of their preset torque directly impacts the quality of equipment assembly. When the loaded torque reaches the preset value, the torque wrench trips (unloads). However, some wrenches may experience secondary unloading (i.e., two consecutive torque peaks) due to the dynamic response characteristics of their internal mechanical structures (such as pawls, springs, and meshing teeth). This secondary unloading can cause the actual tightening torque to deviate from the preset value, affecting assembly accuracy and even posing a safety hazard.

[0003] Existing torque wrench testing methods have many shortcomings. For example, they are unable to comprehensively and accurately evaluate the performance of the torque wrench. In particular, when the torque wrench experiences secondary unloading, it is difficult to analyze the impact of the secondary unloading on the torque measurement value. It is also impossible to consider the relationship between the secondary unloading point and the torque wrench performance from multiple dimensions. As a result, it is impossible to provide users with comprehensive and targeted reference and suggestions, which affects the correct use and maintenance of the torque wrench. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method and device for monitoring the torque value of a prefabricated torque wrench, which can accurately collect test data of the torque wrench, evaluate the performance of the torque wrench from multiple dimensions through analysis and processing of the test data, and especially conduct an in-depth analysis of the secondary unloading situation, thereby providing accurate and comprehensive reference and suggestions for torque wrench users.

[0005] The technical solution adopted by the present invention to solve the technical problem is: a method for monitoring the torque value of a prefabricated torque wrench, comprising the following steps:

[0006] S1. Hardware Connection and Preparation: Place the torque wrench to be tested on the output head of the test bench, so that the torque wrench's force-bearing head is embedded in the test bench's sensor force-bearing square groove, and the torque wrench's lever arm acts on the test bench's support rod and remains horizontal. The test system includes a torque meter and a computer. The torque meter is connected to the test bench's sensor, and the computer is in communication with the torque meter. Press the meter's reset button to reset the meter, and select tracking mode or hold mode as needed.

[0007] S2. Test process: Gradually apply force to the torque wrench. The sensor on the test bench converts the torque into an electrical signal and transmits it to the torque meter. The torque meter displays the torque output value in real time and uploads the data to the computer. The computer receives the data, stores it in the memory, and displays the corresponding points on the screen. Multiple test data points form a test line that reflects the torque loading process.

[0008] S3. Data processing and analysis: Analyze the test line, obtain the first and second unloading points, record the timestamps corresponding to the two unloading points, calculate the time interval between the second unloading points, and consider the second unloading point from the perspective of slip angle. Determine the performance of the torque wrench under test based on the torque values ​​at the two unloading points and the impact of the second unloading.

[0009] S4. Result output: Based on the torque wrench performance evaluation results, provide reference and suggestions to the operator using the torque tool.

[0010] Furthermore, in step S3 of the present invention, the first unloading point and the second unloading point in the test line are identified by a peak detection algorithm or a curve slope change analysis algorithm; the slip angle is obtained by installing an angle sensor on the torque wrench body, or calculated based on the structural parameters and kinematic relationship of the torque wrench.

[0011] Furthermore, in step S3 of the present invention, during a loading process of the torque wrench, the first unloading point is the first tripping peak when loaded to the preset value, recorded as P1, and the second unloading point is the tripping peak that appears again within a short time after the first tripping, recorded as P2; the time interval from the first unloading point P1 to the second unloading point P2 is the elapsed time Δt, in milliseconds; in the process from the first unloading point P1 to the second unloading point P2, the rotation angle of the torque wrench body relative to the force head is the slip angle Δθ, in degrees.

[0012] Furthermore, in step S3 of the present invention, the process of collecting and synchronizing the parameters of the secondary unloading point is as follows:

[0013] Torque data acquisition is achieved by loading torque on a torque test bench. The torque meter detects the torque value in real time and transmits it to the data acquisition module, synchronously recording the timestamp corresponding to each torque value. Angle data acquisition is achieved by installing an angle sensor on the torque wrench body to acquire the rotation angle of the torque wrench body relative to the load-bearing head in real time, and synchronously recording the timestamp corresponding to each angle value. During data synchronization, the data analysis terminal aligns the torque data with the angle data through the timestamp, establishes a torque-time-angle three-dimensional data set, and marks the positions of P1 and P2 on the time axis. That is, through the peak characteristics of the torque curve, P1 is identified as the maximum value before the first torque drop, and P2 is the maximum value before the torque drops again after P1.

[0014] Furthermore, the present invention calculates the elapsed time Δt and the slip angle Δθ between P1 and P2 based on the three-dimensional data set, and analyzes the secondary unloading characteristics based on the correlation between the two:

[0015] When Δθ is the same, the smaller Δt is, the shorter the time interval between the two unloadings is. The energy release of the mechanical structure is not enough and obvious secondary loading occurs. The larger the difference ΔM between the torque peak of P2 and P1 is, where ΔM = M2-M1, M1 is the torque value of P1, and M2 is the torque value of P2. That is, P2 is more obvious. Conversely, the larger Δt is, the more sufficient the energy release is, the more difficult it is to trigger secondary loading, and P2 is more ambiguous.

[0016] When Δt is the same, the larger Δθ is, the greater the relative rotation angle of the mechanical structure during the two unloading processes, the more sufficient the energy release is, and it is difficult to trigger secondary loading. The closer the torque value M2 of P2 is to the stable value after unloading, the less obvious P2 is. Conversely, the smaller Δθ is, the smaller the relative displacement of the mechanical structure is, the less energy is released and obvious secondary loading occurs, and the more obvious P2 is.

[0017] At the same time, the present invention also provides a prefabricated torque wrench torque value monitoring device, comprising a workbench and a torque plate body, wherein a torque sensor for monitoring the torque of the torque plate body is fixedly installed on the top of the workbench, a supporting device for supporting the torque plate body is provided at the top of the workbench, an adjusting device for driving the supporting device to move left and right is provided in the workbench, and a monitoring fixing device for monitoring the torque of the torque plate body is provided at the top of the workbench; the adjusting device comprises a moving component arranged at the top of the workbench for supporting the supporting device, a driving component for driving the moving component to move left and right is provided in the workbench, the supporting device comprises a supporting plate arranged above the moving component for supporting the torque plate body, a height adjustment component for adjusting the height of the support plate is fixedly installed on the top of the moving component; the monitoring fixing device comprises a monitoring component arranged at the top of the workbench for monitoring the torque of the torque plate body, a fixing component for detecting the angle of the torque plate body is provided on the torque plate body, and the fixing component is electrically connected to the monitoring component.

[0018] Specifically, a long slot for placing the driving assembly is provided at the top of the workbench, and four supporting legs are fixedly installed at the bottom of the workbench for supporting the workbench.

[0019] Specifically, the driving assembly includes a threaded rod arranged in the long slot for driving the moving assembly to move left and right, and a handwheel for driving the threaded rod to rotate is fixedly installed on the right end of the threaded rod.

[0020] Specifically, the moving assembly includes a threaded sleeve plate arranged in the long slot for threaded connection with the threaded rod, and a fixing plate for supporting the supporting device is fixedly installed on the top end of the threaded sleeve plate.

[0021] Specifically, the height adjustment assembly includes four support columns fixedly mounted on the top of the fixed plate, and a plurality of locking holes are formed on the column bodies of the support columns.

[0022] Specifically, a connecting column for moving up and down is provided in the support column, and a limiting plate is fixedly installed at the bottom end of the connecting column to prevent the connecting column from moving out of the support column. A locking rod is provided in the cavity of the locking hole to fix the limiting plate in the support column.

[0023] Specifically, the monitoring component includes a torque meter fixedly mounted on the top of the workbench for connecting to the torque sensor via wires, and a display screen fixedly mounted on the top of the workbench for connecting to the torque meter.

[0024] Specifically, the fixing assembly includes two fixing rings that are mounted on the torque plate body. An angle sensor for monitoring the angle of the torque plate body is fixedly installed on the top of the upper fixing ring, and the angle sensor is connected to the torque meter. Bolts are provided between the two fixing rings to fix the two fixing rings on the torque plate body.

[0025] The beneficial effect of the present invention is to solve the defects existing in the background technology.

[0026] 1. By combining hardware connection and software analysis, the test data of the torque wrench can be collected comprehensively and accurately, and the data can be deeply analyzed. The secondary unloading point is considered from two dimensions: elapsed time and slip angle. Compared with existing technologies, the performance of the torque wrench can be evaluated more comprehensively.

[0027] 2. It can accurately judge the influence of the second unloading on the unloading value measurement of the entire torque wrench, and provide specific and practical reference and suggestions for torque wrench users, which will help users to correctly operate and maintain the torque wrench and improve work efficiency and quality.

[0028] 3. The test process is highly automated, and test data is processed and analyzed by software, which reduces manual intervention and improves the accuracy and reliability of test results.

[0029] 4. The driving assembly (threaded rod + handwheel) drives the mobile assembly to move horizontally. Combined with the height-adjustable support device (support column + locking hole + connecting column), the torque wrench body can be flexibly adapted in terms of horizontal position and support height, ensuring that wrenches of different specifications always remain horizontal during testing, eliminating measurement errors caused by installation offset.

[0030] 5. Dynamic torque-angle collaborative monitoring, integrating the fixing components of the torque sensor and angle sensor (double fixing ring + bolt), synchronously collects the torque value and wrench deflection angle in real time; through the linkage between the torque meter and the display screen, it simultaneously outputs the horizontal axis time-vertical axis torque value curve, real-time / peak torque, slip angle, torque angle and other key parameters, intuitively reflecting the dynamic performance of the wrench and providing multi-dimensional data support for quality assessment. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic diagram of the overall structure of the device of the present invention;

[0032] Figure 2 A cross-sectional view of a working table of the device of the present invention;

[0033] Figure 3 It is a schematic structural diagram of the regulating device of the device of the present invention;

[0034] Figure 4 Schematic diagram of the supporting device structure of the device of the present invention;

[0035] Figure 5 For the present invention Figure 4 Enlarged view of point A in the middle;

[0036] Figure 6 This is a schematic diagram of the structure of the monitoring fixture of the device of the present invention;

[0037] Figure 7 For the present invention Figure 6 Enlarged view of point B in the middle;

[0038] Figure 8 This is a flow chart of the monitoring method of the present invention;

[0039] In the figure: 100, workbench; 101, long slot; 102, support leg; 200, torque sensor; 300, adjustment device; 310, drive assembly; 311, threaded rod; 312, handwheel; 320, moving assembly; 321, threaded sleeve; 322, fixed plate; 400, support device; 410, support plate; 420, height adjustment assembly; 421, support column; 422, locking hole; 423, connecting column; 424, limiting plate; 425, locking rod; 500, monitoring fixture; 510, monitoring assembly; 511, torque meter; 512, display screen; 520, fixing assembly; 521, angle sensor; 522, fixing ring; 523, bolt; 600, torque wrench body. DETAILED DESCRIPTION

[0040] The present invention will now be described in further detail with reference to the accompanying drawings and preferred embodiments. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0041] like Figures 1-8 As shown, a prefabricated torque wrench torque value monitoring device includes a workbench 100 and a torque plate body 600. A torque sensor 200 for monitoring the torque of the torque plate body 600 is fixedly installed on the top of the workbench 100. A supporting device 400 for supporting the torque plate body 600 is provided on the top of the workbench 100. An adjusting device 300 for driving the supporting device 400 to move left and right is provided in the workbench 100. A monitoring fixing device 500 for monitoring the torque of the torque plate body 600 is provided on the top of the workbench 100; the adjusting device 300 includes a moving component provided on the top of the workbench 100 for supporting the supporting device 400. 320, a driving component 310 for driving the moving component 320 to move left and right is provided in the workbench 100, the supporting device 400 includes a supporting plate 410 arranged above the moving component 320 for supporting the torque plate sub-body 600, and a height adjustment component 420 for adjusting the height of the support plate 410 is fixedly installed on the top of the moving component 320; the monitoring fixing device 500 includes a monitoring component 510 arranged at the top of the workbench 100 for torque monitoring of the torque plate sub-body 600, and a fixing component 520 for angle monitoring of the torque plate sub-body 600 is provided on the torque plate sub-body 600, and the fixing component 520 is electrically connected to the monitoring component 510.

[0042] In one embodiment of the present invention, Figure 2 As shown, a long slot 101 for placing the drive assembly 310 is provided at the top of the workbench 100, and a support leg 102 for supporting the workbench 100 is fixedly installed at the bottom end of the workbench 100, and there are four support legs 102. The four support legs 102 are welded in a rectangular array at the bottom end of the workbench 100, so the four support legs 102 can be conveniently used to support the workbench 100; the torque sensor 200 is a detection of the torsional moment perception on various rotating or non-rotating mechanical parts; therefore, the torque sensor 200 can be used to monitor the torque of the torque plate body 600 in real time.

[0043] In one embodiment of the present invention, Figure 2 and Figure 3As shown, the driving assembly 310 includes a threaded rod 311 arranged in the long slot 101 for driving the moving assembly 320 to move left and right, and the left and right ends of the threaded rod 311 are connected by bearings, so that the rotation of the threaded rod 311 can be facilitated; the right end of the threaded rod 311 is fixedly installed with a handwheel 312 for driving the threaded rod 311 to rotate.

[0044] Furthermore, the moving assembly 320 includes a threaded sleeve 321 arranged in the long groove 101 for threaded connection with the threaded rod 311, and the shape and size of the threaded sleeve 321 are the same as the shape and size of the long groove 101. Therefore, when the threaded rod 311 rotates, the threaded sleeve 321 can always keep moving left and right along the threaded rod 311, so it can be quickly adjusted according to the length of the torque wrench body 600; the top of the threaded sleeve 321 is fixedly installed with a fixing plate 322 for supporting the supporting device 400; therefore, when the torque wrench body 600 needs to be supported according to its size, the threaded rod 311 can be driven to rotate by the handwheel 312, and the threaded sleeve 321 can move left and right along the threaded rod 311, so that the supporting device 400 on the fixing plate 322 can be used to adjust the length of the torque wrench body 600 from the torque sensor 200.

[0045] In one embodiment of the present invention, Figure 3 、 Figure 4 and Figure 5 As shown, the height adjustment assembly 420 includes a support column 421 fixedly mounted on the top of the fixed plate 322, and there are four support columns 421, which are welded in a rectangular array on the top of the fixed plate 322; and the internal cavity of the support column 421 is stepped; a plurality of locking holes 422 are opened on the column body of the support column 421, and the plurality of locking holes 422 are distributed in a linear array on the column body of the support column 421.

[0046] Furthermore, a connecting column 423 for moving up and down is provided in the support column 421, and a limiting plate 424 is fixedly installed at the bottom end of the connecting column 423 to prevent the connecting column 423 from moving out of the support column 421, and a locking rod 425 is provided in the cavity of the locking hole 422 to fix the limiting plate 424 in the support column 421; so that when the torque plate body 600 on the torque sensor 200 needs to be kept horizontal, a tool can be used to embed the force head of the torque plate body 600 into the force square groove of the torque sensor 200; and then the limiting plate 424 is used to fix the support column 4 21 moves up and down to control the support plate 410 on the connecting column 423 to adjust up and down; then the locking rod 425 passes through the locking hole 422, so that the limiting plate 424 can be fixed in the support column 421; therefore, the torque plate body 600 on the torque sensor 200 can be kept horizontal; then the handwheel 312 drives the threaded rod 311 to rotate, and the threaded sleeve 321 can move left and right along the threaded rod 311, so that the support device 400 on the fixed plate 322 can be used to adjust the length of the torque wrench body 600 from the torque sensor 200.

[0047] In one embodiment of the present invention, Figure 6 and Figure 7 As shown, the monitoring component 510 includes a torque meter 511 fixedly installed on the top of the workbench 100 for connecting to the torque sensor 200 through wires, and the torque meter 511 is of model HBF2-200 and adopts high-precision AD; the torque meter 511 of model HBF2-200 has a measurement range of 2-200Nm and an accuracy of 0.3 level; it is divided into two ranges of 2Nm-20Nm and 20Nm-200Nm; a display screen 512 for connecting to the torque meter 511 is fixedly installed on the top of the workbench 100, wherein the display screen 512 is a large-size color display instrument with a touch function to collect real-time torque test signals, upload the collected data to the computer for data processing, draw real-time loading curves, and analyze loading characteristics; wherein the display screen 512 has expandable channels and has an interface for connecting to a computer to upload data.

[0048] Furthermore, the fixing assembly 520 includes a fixing ring 522 mounted on the torque plate body 600, and there are two fixing rings 522, and the two fixing rings 522 are symmetrically distributed on the torque plate body 600 in the upper and lower directions; an angle sensor 521 for monitoring the angle of the torque plate body 600 is fixedly installed on the top of the upper fixing ring 522, and the angle sensor 521 is connected to the torque meter 511, wherein the angle measurement range of the angle sensor 521 is 0-180 degrees, and the accuracy is 0.05 degrees; a bolt 523 for fixing the two fixing rings 522 on the torque plate body 600 is provided between the two fixing rings 522; therefore, the bolt 523 can be used to pass through the two fixing rings 522 to install the angle sensor 521 on the torque plate body 600, so as to monitor the angle in real time when the torque plate body 600 is rotated.

[0049] The process of torque wrench monitoring is as follows:

[0050] S1: The torque plate body 600 to be measured is placed on the output head of the torque sensor 200, and the force-bearing head of the tool is embedded in the force-bearing square groove of the torque sensor 200, so that the force arm lever of the torque plate body 600 acts on the support plate 410 of the workbench 100 to keep the torque plate body 600 horizontal; then, the limiting plate 424 is moved up and down in the support column 421 to control the up and down adjustment of the support plate 410 on the connecting column 423; then, the locking rod 425 is passed through the locking hole 422 to fix the limiting plate 424 in the support column 421; thus, the torque plate body 600 on the torque sensor 200 can be kept horizontal; then, the handwheel 312 is used to drive the threaded rod 311 to rotate, and the threaded sleeve 321 can move left and right along the threaded rod 311, so that the support device 400 on the fixing plate 322 can be used to adjust the distance between the torque wrench body 600 and the torque sensor 200.

[0051] S2: Put the two fixing rings 522 on the torque plate body 600, and use the bolts 523 to fix the two fixing rings 522 on the torque plate body 600, so that the reset button of the torque meter 511 is reset to zero; the measurement mode of the torque meter 511 is selected as tracking mode or holding mode as needed; then the data recorded by the angle sensor 521 is displayed on the display screen 512 to keep the torque plate body 600 level.

[0052] S3: The torque plate body 600 is gradually subjected to angular force, and the torque meter 511 displays the torque output value and angle of the torque plate body 600 in real time and uploads the data to the display screen 512.

[0053] S4: When the loading torque reaches a preset value, the torque plate body 600 will trip, stop loading, and record the test data through the display screen 512.

[0054] In one embodiment of the present invention, Figure 8 As shown, the monitoring method includes the following steps:

[0055] (1) Hardware connection and preparation

[0056] The test bench is equipped with an output head, a sensor force-bearing square slot, and a support rod. The sensor force-bearing square slot is designed to mate with the torque wrench's force-bearing head, while the support rod is designed to leverage the torque wrench's force arm. The torque wrench to be tested is placed on the test bench's output head, with the tool's force-bearing head embedded in the test bench's sensor force-bearing square slot. This ensures a tight fit and accurate torque transmission. The wrench's force arm leverages the test bench's support rod, and the torque wrench is kept horizontal to ensure the force is applied in the correct direction during testing, reducing test errors caused by improper installation.

[0057] The test system also includes a torque meter and a computer. The torque meter is connected to the test bench's sensor to receive, process, and display the torque signal transmitted by the sensor. The computer is connected to the torque meter to collect test data. Before testing, press the "Zero" button on the meter to reset the meter to eliminate initial errors. Based on the test requirements, the measurement mode can be selected through the meter's operation interface. Tracking mode provides real-time display of torque changes, while hold mode maintains the displayed value after reaching a certain value, facilitating data recording and observation.

[0058] (2) Testing process

[0059] Gradually apply force to the torque wrench. During this process, the test bench's sensor converts the torque it senses into an electrical signal, which is transmitted to the torque meter. The torque meter processes the signal and displays the torque output value in real time. Simultaneously, the torque meter uploads the torque data to a computer via a communication interface (such as a serial port, USB port, or network interface). After receiving the data, the computer stores it in memory and displays the corresponding torque value as dots on the screen. As the test progresses, multiple test data points are connected on the screen to form a test line. This test line intuitively reflects the torque loading process, allowing testers to observe torque trends.

[0060] (3) Data processing and analysis

[0061] The software analyzes the test line and identifies the first and second unloading points in the test line using specific algorithms (such as peak detection and curve slope change analysis). The first unloading point is the point where the torque wrench first experiences a drop in torque during loading, and the second unloading point is the point where the torque drops again after the first unloading.

[0062] The loading line is analyzed, and the software records the timestamps corresponding to the two unloading points, calculating the time interval between the two unloading points. The software also considers the second unloading point from the perspective of the slip angle. The slip angle can be determined by installing an angle sensor on the wrench body or by calculating based on the torque wrench's structural parameters and kinematic relationships. Theoretically, at the same slip angle, the shorter the time interval between the two unloading points, the more pronounced the torque peak formed during the second unloading; at the same time, the larger the slip angle, the less pronounced the torque peak formed during the second unloading. By analyzing the two dimensions of elapsed time and slip angle, a comprehensive assessment is made of the extent to which the second unloading affects the unloading value measurement of the entire torque wrench.

[0063] The software evaluates the performance of the torque wrench under test based on an analysis of the torque values ​​at the two unloading points and a determination of the impact of the second unloading. For example, if the torque value at the second unloading point is slightly different from the first, with a short time interval and a small slip angle, the torque wrench's performance is relatively stable, and the second unloading has little impact on the torque measurement. Conversely, if the difference is significant, the torque wrench may have performance issues and require further inspection and adjustment.

[0064] The method for determining the secondary unloading point of a torque wrench based on elapsed time and slip angle includes the following steps:

[0065] Step 1: Define secondary unloading points and core parameters

[0066] Secondary unloading point: refers to the torque peak points corresponding to the two obvious unloading (tripping) behaviors that occur in the torque wrench during one loading process. The first unloading point is the first tripping peak when loaded to the preset value (denoted as P1), and the second unloading point is the tripping peak that appears again shortly after the first tripping (denoted as P2).

[0067] Elapsed time (Δt): refers to the time interval from the first unloading point P1 to the second unloading point P2, measured in milliseconds (ms), reflecting the time correlation between the two unloading operations.

[0068] Slip angle (Δθ): refers to the rotation angle of the torque wrench body relative to the load-bearing head from the first unloading point P1 to the second unloading point P2. The unit is degree (°), reflecting the relative displacement of the mechanical structure during the two unloading processes.

[0069] Step 2: Collection and synchronization of secondary unloading point parameters

[0070] Torque data acquisition: Torque is applied through the torque test bench, and the torque instrument detects the torque value in real time and transmits it to the data acquisition module, which also records the timestamp corresponding to each torque value (provided by the time synchronization module, with an accuracy of ≥0.1ms).

[0071] Angle data collection: An angle sensor (such as a photoelectric encoder with a resolution of ≥0.1°) is installed on the torque wrench body to collect the relative rotation angle between the two in real time and synchronously record the timestamp corresponding to each angle value.

[0072] Data synchronization: The data analysis terminal aligns the torque data with the angle data through timestamps to create a three-dimensional "torque-time-angle" data set, marking the positions of P1 and P2 on the time axis (identified by the peak characteristics of the torque curve: P1 is the maximum value before the first torque drop, and P2 is the maximum value before the torque drops again after P1).

[0073] Step 3: Quantitative analysis of the secondary unloading point based on Δt and Δθ

[0074] Based on the three-dimensional data set, the elapsed time Δt and slip angle Δθ between P1 and P2 are calculated, and the secondary unloading characteristics are analyzed based on the correlation between the two:

[0075] 1. Influence of Δt at the same slip angle (fixed Δθ): When Δθ is the same, a smaller Δt indicates a shorter time interval between unloading events, more concentrated energy release in the mechanical structure, and a larger difference between the torque peak of P2 and P1 (ΔM = M2 - M1, where M1 is the torque value of P1 and M2 is the torque value of P2). This indicates a more pronounced P2 (e.g., when Δt ≤ 50 ms, ΔM is typically ≥ 10% of M1). Conversely, a larger Δt indicates a more gradual energy dissipation between unloading events, making P2 more ambiguous (e.g., when Δt ≥ 200 ms, ΔM may be ≤ 3% of M1).

[0076] 2. Influence of Δθ under the same elapsed time (fixed Δt): When Δt is the same, the larger Δθ is, the greater the relative rotation angle of the mechanical structure during the two unloading processes, the more energy dissipated by friction, the closer the torque value M2 of P2 is to the stable value after unloading, and the less obvious P2 is (for example, when Δθ ≥ 5°, ΔM may be ≤ 5% M1); conversely, the smaller Δθ is, the smaller the relative displacement of the mechanical structure, the less energy dissipated, and the more obvious P2 is (for example, when Δθ ≤ 2°, ΔM is usually ≥ 8% M1).

[0077] Step 4: Wrench performance evaluation and recommendations based on analysis results

[0078] The data analysis terminal generates performance evaluation results based on the values ​​of Δt, Δθ, and ΔM, combined with preset thresholds (which can be adjusted according to the wrench type), as shown in the following table:

[0079]

[0080] (IV) Result output

[0081] Based on the torque wrench performance evaluation results, the software provides reference and suggestions to the operator using this torque tool. For example, if secondary unloading has a significant impact on the torque measurement value, the operator is advised to pay attention to operational factors such as loading speed and loading method when using the torque wrench to avoid measurement errors due to improper operation. Alternatively, the operator is advised to calibrate the torque wrench, repair it, or replace parts to ensure that the torque wrench's performance meets the requirements.

[0082] The above description only describes specific embodiments of the present invention. Various examples do not limit the essential content of the present invention. After reading the description, ordinary technicians in the relevant technical field can make modifications or variations to the specific embodiments described above without departing from the essence and scope of the invention.

Claims

1. A method for monitoring torque values ​​of a prefabricated torque wrench, characterized by: The following steps are included: S1. Hardware Connection and Preparation: Place the torque wrench to be tested on the output head of the test bench, so that the torque wrench's force-bearing head is embedded in the test bench's sensor force-bearing square groove, and the torque wrench's lever arm acts on the test bench's support rod and remains horizontal. The test system includes a torque meter and a computer. The torque meter is connected to the test bench's sensor, and the computer is in communication with the torque meter. Press the meter's reset button to reset the meter, and select tracking mode or hold mode as needed. S2. Test process: Gradually apply force to the torque wrench. The sensor on the test bench converts the torque into an electrical signal and transmits it to the torque meter. The torque meter displays the torque output value in real time and uploads the data to the computer. The computer receives the data, stores it in the memory, and displays the corresponding points on the screen. Multiple test data points form a test line that reflects the torque loading process. S3. Data processing and analysis: Analyze the test line, obtain the first and second unloading points, record the timestamps corresponding to the two unloading points, calculate the time interval between the second unloading points, and consider the second unloading point from the perspective of slip angle. Determine the performance of the torque wrench under test based on the torque values ​​at the two unloading points and the impact of the second unloading. S4. Result output: Based on the torque wrench performance evaluation results, provide reference and suggestions to the operator using the torque tool.

2. The method for monitoring torque value of a prefabricated torque wrench according to claim 1, characterized in that: In step S3, the first unloading point and the second unloading point in the test line are identified by a peak detection algorithm or a curve slope change analysis algorithm; the slip angle is obtained by installing an angle sensor on the torque wrench body, or is calculated based on the structural parameters and kinematic relationship of the torque wrench.

3. The method for monitoring torque value of a prefabricated torque wrench according to claim 2, characterized in that: In step S3, during a loading process of the torque wrench, the first unloading point is the first tripping peak when loaded to the preset value, recorded as P1, and the second unloading point is the tripping peak that appears again within a short time after the first tripping, recorded as P2; the time interval from the first unloading point P1 to the second unloading point P2 is the elapsed time Δt, in milliseconds; during the process from the first unloading point P1 to the second unloading point P2, the rotation angle of the torque wrench body relative to the load-bearing head is the slip angle Δθ, in degrees.

4. The method for monitoring torque value of a prefabricated torque wrench according to claim 3, characterized in that: In step S3, the process of collecting and synchronizing the parameters of the secondary unloading point is as follows: Torque data is collected by loading torque on a torque test bench. The torque meter detects the torque value in real time and transmits it to the data acquisition module, synchronously recording the timestamp corresponding to each torque value. Angle data is collected by installing an angle sensor on the torque wrench body to collect the rotation angle of the torque wrench body relative to the load-bearing head in real time, and synchronously recording the timestamp corresponding to each angle value. During data synchronization, the data analysis terminal aligns the torque data and angle data through the timestamp to establish a torque-time-angle three-dimensional data set, marking the positions of P1 and P2 on the time axis. That is, through the peak characteristics of the torque curve, P1 is the maximum value before the first torque drop, and P2 is the maximum value before the torque drops again after P1.

5. The method for monitoring torque value of a prefabricated torque wrench according to claim 4, characterized in that: Based on the three-dimensional data set, the elapsed time Δt and slip angle Δθ between P1 and P2 are calculated, and the secondary unloading characteristics are analyzed based on the correlation between the two: When Δθ is the same, the smaller Δt is, the shorter the time interval between the two unloadings is. The energy release of the mechanical structure is not enough and obvious secondary loading occurs. The larger the difference ΔM between the torque peak of P2 and P1 is, where ΔM = M2-M1, M1 is the torque value of P1, and M2 is the torque value of P2. That is, P2 is more obvious. Conversely, the larger Δt is, the more sufficient the energy release is, the more difficult it is to trigger secondary loading, and P2 is more ambiguous. When Δt is the same, the larger Δθ is, the greater the relative rotation angle of the mechanical structure during the two unloading processes, the more sufficient the energy release is, and it is difficult to trigger secondary loading. The closer the torque value M2 of P2 is to the stable value after unloading, the less obvious P2 is. Conversely, the smaller Δθ is, the smaller the relative displacement of the mechanical structure is, the less energy is released and obvious secondary loading occurs, and the more obvious P2 is.

6. A monitoring device used in the method for monitoring the torque value of a prefabricated torque wrench according to claim 1, characterized in that: The invention comprises a workbench (100) and a torque plate body (600), wherein a torque sensor (200) for monitoring the torque of the torque plate body (600) is fixedly installed on the top of the workbench (100), a supporting device (400) for supporting the torque plate body (600) is provided on the top of the workbench (100), an adjusting device (300) for driving the supporting device (400) to move left and right is provided in the workbench (100), a monitoring fixing device (500) for monitoring the torque of the torque plate body (600) is provided on the top of the workbench (100); the adjusting device (300) comprises a moving component (320) provided on the top of the workbench (100) for supporting the supporting device (400), and the workbench (100) is provided with a plurality of adjusting devices (300) for driving the supporting device (400) to move left and right. 00) is provided with a driving assembly (310) for driving the moving assembly (320) to move left and right, the supporting device (400) includes a supporting plate (410) provided above the moving assembly (320) for supporting the torque plate sub-body (600), and a height adjustment assembly (420) for adjusting the height of the support plate (410) is fixedly installed on the top of the moving assembly (320); the monitoring fixing device (500) includes a monitoring assembly (510) provided on the top of the workbench (100) for monitoring the torque of the torque plate sub-body (600), and a fixing assembly (520) for detecting the angle of the torque plate sub-body (600) is provided on the torque plate sub-body (600), and the fixing assembly (520) is electrically connected to the monitoring assembly (510).

7. The method for monitoring torque value of a prefabricated torque wrench according to claim 6, characterized in that: The top of the workbench (100) is provided with a long slot (101) for placing the driving assembly (310), and the bottom of the workbench (100) is fixedly installed with supporting legs (102) for supporting the workbench (100), and there are four supporting legs (102); the driving assembly (310) includes a threaded rod (311) arranged in the long slot (101) for driving the moving assembly (320) to move left and right, and the right end of the threaded rod (311) is fixedly installed with a hand wheel (312) for driving the threaded rod (311) to rotate; the moving assembly (320) includes a threaded sleeve (321) arranged in the long slot (101) for being threadedly connected to the threaded rod (311), and the top of the threaded sleeve (321) is fixedly installed with a fixed plate (322) for supporting the supporting device (400).

8. The method for monitoring torque value of a prefabricated torque wrench according to claim 6, characterized in that: The height adjustment assembly (420) includes a support column (421) fixedly mounted on the top of the fixed plate (322), and there are four support columns (421). A plurality of locking holes (422) are provided on the column body of the support column (421); a connecting column (423) for moving up and down is provided in the support column (421), a limiting plate (424) for preventing the connecting column (423) from moving out of the support column (421) is fixedly mounted at the bottom end of the connecting column (423), and a locking rod (425) for fixing the limiting plate (424) in the support column (421) is provided in the cavity of the locking hole (422).

9. The method for monitoring torque value of a prefabricated torque wrench according to claim 6, characterized in that: The monitoring assembly (510) includes a torque meter (511) fixedly mounted on the top of a workbench (100) and connected to a torque sensor (200) via a wire. A display screen (512) is fixedly mounted on the top of the workbench (100) and connected to the torque meter (511).

10. The method for monitoring torque value of a prefabricated torque wrench according to claim 6, characterized in that: The fixing assembly (520) includes a fixing ring (522) mounted on the torque plate body (600), and there are two fixing rings (522). An angle sensor (521) for monitoring the angle of the torque plate body (600) is fixedly installed on the top of the upper fixing ring (522), and the angle sensor (521) is connected to the torque meter (511). A bolt (523) is provided between the two fixing rings (522) for fixing the two fixing rings (522) to the torque plate body (600).

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