Method for displaying the tightening level of fasteners to the user

Abstract

The invention relates to a method for displaying the tightening level to the person who is tightening the fastener, based on the torque level increasing during the installation of the fastener.

Description

[0001] METHOD FOR DISPLAYING THE TIGHTENING LEVEL OF FASTENERS TO THE USER

[0002] TECHNICAL FIELD

[0003] The invention relates to a method for displaying the tightening level to the person who is tightening the fastener, based on the torque level increasing during the installation of the fastener.

[0004] PRIOR ART

[0005] A bolt is a fastener that is tightened with a nut to secure the parts intended to be joined by opening holes into them. Bolts can be made of materials such as iron, steel, stainless steel, bronze, titanium, copper, aluminum, and are most commonly produced as iron-steel alloy types in the construction industry. The length of the bolt and its load-bearing capacity are calibrated to meet the appropriate production standards depending on the intended application. A bolt consists of two parts: the head and the shank. The head, which includes elements like a hex head or similar shape, is used for turning during installation. The bolt is tightened by rotating the head, and it is designed so that its threads can fit into the threads of the nut or the threaded hole in the part being fastened. During installation, the bolt head is tightened by turning it from the head using a hex key, torque wrench, or a similar tool in a way that joins the components to be assembled. In this process, the threads on the bolt must match the thread pitch of the nut or the threaded part of the assembled component. During assembly, as the bolt is turned from the head section with the help of a wrench and tightened, it is clamped between the head section and the nut or the other threaded assembly surface. As the torque increases during tightening, the stress / strain on the body section and the threads increases. If it is over-tightened, there is a risk of thread stripping and the formation of microcracks in the body. This situation poses a risk for the continued safe retention of the assembled parts.

[0006] When the claims regarding smart bolts introduced within the scope of applications in the known technique are examined, it is seen that smart bolts focus on loosening caused by vibrations and external factors after assembly. It is observed that the risks that may arise due to deformation in the structure of the bolt as a result of being exposed to excessive tightening load during the initial assembly, or due to insufficient tightening, are not thoroughly addressed. Although suggestions such as performing measurements with the help of sensors are frequently encountered within the scope of existing solutions, it is difficult to find application areas due to the fact that it is not possible to use sensors in all usage areas of bolts and that the use of advanced technology significantly increases the required labor qualifications.

[0007] BRIEF DESCRIPTION OF THE INVENTION

[0008] The invention relates to a method for indicating the tightening level of a fastener, which enables monitoring the tightening intensity of the fastener without requiring expertise and addresses the technical problems encountered in the known technique. Through the method subject to the invention, the tightening level of the fastener is visually displayed to the user during the tightening process until the calibrated limit is reached. The method according to the invention is based on displaying the tightening level to the user through a color change visible on the head of the fastener as it is being tightened. The colored liquid used to show this color change is non-toxic and is calibrated by taking into account the fluidity (density) suitable for the fastener (its usage area, conditions, and environmental factors). In this way, the tightening level of the fastener can be monitored mechanically by the person tightening it, without the need for complex and expertise-demanding electronic equipment.

[0009] LIST OF FIGURES

[0010] Figure 1. General View of Smart Bolt

[0011] Figure 2. Cross-sectional View A-A of Smart Bolt

[0012] Figure 3. Detailed View A of Smart Bolt

[0013] Figure 4. Top View of Opaque Body

[0014] Figure 5. Side View of Opaque Body

[0015] Figure 6. Cross-sectional View B-B of Opaque Body

[0016] Figure 7. Perspective View of Lower Body

[0017] Figure 8. Side View of Lower Body

[0018] Figure 9. Cross-sectional View C-C of Lower Body

[0019] Figure 10. Side View of Shaft Cap

[0020] Figure 11. Cross-sectional View D-D of Shaft Cap

[0021] Figure 12. Top View of O-ring

[0022] Figure 13. Side View of O-ring Figure 14. Cross-sectional View E-E of O-ring

[0023] Figure 15. Top View of Colored Liquid

[0024] Figure 16. Side View of Colored Liquid

[0025] Figure 17. Cross-sectional View F-F of Colored Liquid

[0026] Figure 18. Top View of Reflector

[0027] Figure 19. Side View of Reflective Liquid

[0028] Figure 20. Cross-sectional View F-F of Reflective Liquid

[0029] Correspondence of the Numbers Shown in the Figures

[0030] 1 . Head

[0031] 2. Body

[0032] 3. Tightening Level Indicator

[0033] 3.1 . Opaque Body

[0034] 3.2. Lower Body

[0035] 3.3. Shaft

[0036] 3.4. Shaft Cap

[0037] 3.5. O-ring

[0038] 3.6. Colored Liquid

[0039] 3.7. Reflector

[0040] DETAILED DESCRIPTION OF THE INVENTION

[0041] The invention relates to a method of displaying the tightening level in real-time based on torque using a tightening level indicator (3) consisting of parts and components such as the opaque body (3.1 ), lower body (3.2), shaft (3.3), shaft cap (3.4), o-ring (3.5), colored liquid (3.6), and reflector (3.7), which is integrated into the fastener consisting of a head (1 ) and body (2).

[0042] The opaque body (3.1 ) and lower body (3.2) parts are manufactured using plastic injection molding techniques. Polyamide GF30, a thermoplastic with a high level of reinforcement, uniformity, and volume stability, is used to form parts ideal for automatic mass production. After steel molds are created that imitate the exact shape of the opaque body (3.1 ) and lower body (3.2), molten Polyamide GF30 plastic is injected into these molds under high pressure to fill all gaps, forming the part, which solidifies within the mold. Once cooled, the formed parts are removed from the mold for further finishing operations. The shaft (3.3) is produced by machining. In this process, the material is precisely extracted from a metal rod by a CNC (computer numerical control) machine, which is digitally programmed to form the dimensions of the shaft.

[0043] The shaft cap (3.4) is produced by injection molding. Similar to the production process of the opaque body (3.1 ) and lower body (3.2), it is manufactured using polyamide GF30 plastic through plastic injection molding.

[0044] The O-ring (3.5) is manufactured by rubber molding. Uncured rubber is pressed into a mold cavity shaped to the desired O-ring (3.5) form. Depending on the type of rubber used, the process is completed by curing the rubber through pressure or chemical reaction.

[0045] The colored liquid (3.6) is prepared using an automatic liquid dosing control unit and injected into the mechanism. The calibration of the fastener is done according to the torque required for tightening. Since torque requirement changes with fastener size (for example, the torque needed for an M16 bolt is much higher than for an M12 one), a sensitive calibration method is necessary. In the method of the invention, the required torque is correlated with the viscosity of the colored liquid inside the fastener. The larger the size of the fastener, the higher the viscosity of the colored liquid should be. This means different colored liquids should be used for different types of fasteners. In the method of the invention, the colored liquid (3.6), which is non-toxic, safe, and dyebased, is calibrated according to the fastener’s use area (location, conditions, environmental factors) and standards of the country in which it is to be used. Similarly, the color of the colored liquid (3.6) is determined according to the fastener’s use area and legal standards of the country of use.

[0046] The reflector (3.7) is embedded into the opaque body (3.1 ). Transparent GF30 plastic is used for this part. Opaque body (3.1 ) and lower body (3.2) are formed by plastic injection molding, while reflector (3.7) is shaped in a special mold for the required reflective surface.

[0047] To bond the opaque body (3.1 ) to the lower body (3.2), ultrasonic plastic welding is used. In this process, to create a strong and clean weld, high-frequency sound waves are used. The bonding surfaces of the opaque body (3.1 ) and the lower body (3.2) are carefully cleaned and aligned. With a special welding tip, high-frequency ultrasonic vibrations are applied to the bonding interface. These vibrations generate friction and heat, softening the plastic material. As the plastic softens, the materials from both parts melt and fuse together, forming a strong bond upon solidification. To ensure that the plastic fully solidifies and a permanent, high-quality bond is formed, it is kept under pressure for a predetermined period of time. Afterward, a simple hydraulic press mechanism is used to apply pressure, embedding the machined fastener into the designated housing inside the mechanism. This ensures that the fastener is securely positioned in the predefined slot within the mechanism.

[0048] Once the fastener is placed in the designated position, the user begins tightening it using a wrench on the head (1 ). As the user continues tightening, the increasing stress in the shaft (3.3), due to rising tension in the body (2) of the fastener, causes the shaft cap (3.4) to push downward. The shaft (3.3), with its downward motion, begins to push the O-ring (3.5), colored liquid (3.6), and reflector (3.7) downward. The colored liquid (3.6) level becomes visible to the user through the reflector (3.7). In this way, the applied torque can be monitored in real time. Based on pre-calibration data (obtained through charts or data-matched codes / barcodes), the torque value is correlated with the liquid level. By tracking the fluid level, one can ensure the fastener is tightened to the desired torque level. With the method subject to the invention, visual monitoring of torque can be achieved without the need for tools or complex measurements. This method provides an intuitive and open way for users to ensure proper tightening of fasteners based on torque. It enables reliable tightening without the need for electronic torque sensors or torque wrenches and helps avoid insufficient or excessive tightening during installation. Thus, reliable fastenings are achieved.

[0049] In this method, replacing the colored liquid (3.6) depends on the movement of the shaft (3.3) and the shaft cap (3.4). A series of tests is used to calibrate the torque value applied to the shaft (3.3) and its relationship to the liquid displacement. A variety of torque levels are calibrated into the fastener containing the tightening level indicator (3) and used with a special wrench. During actual use, the torque applied to the fastener and the liquid displacement inside the indicator (3) are both recorded. The collected data is used to establish a correlation between liquid level and applied torque. This correlation may be presented as a reference chart or a fluid level guide readable by the user. To convert the tightening level to a torque indicator, a code decoding mechanism is integrated into the fastener design.

[0050] The method of the invention is applicable to all fasteners and offers a mechanical alternative system that is easy to use, does not require expertise, is cost- effective, and user-friendly, unlike existing complex solutions based on electronic sensors. Thus, it is possible to manufacture a fastener that does not require electronic hardware or chemicals, that is easy to use, does not need a display, battery, or complicated storage conditions, and that can be operated by anyone.

[0051] The method subject to this patent application is based on the claim of forming a mechanical torque indicator system and producing a fastener that is low-cost, user- friendly, and practical. It provides a practical solution that offers appropriate and accurate results. This invention defines a new and improved method for fasteners to monitor tightening level based on torque, supporting real-time feedback. Thanks to this method, the created fastener becomes a user-friendly and low-cost alternative to existing complex and sensor-based systems. It eliminates the need for complicated electronics, reduces production costs, and simplifies usage with commonly available materials. With this invention, real-time and visually observable torque level monitoring is enabled without the need for complex measurement tools. Due to its independent design, the invention simplifies integration with existing fastener architectures. Polyamide GF30 offers strength and compatibility with various environmental conditions. The invention aims to benefit from economical and mass-production methods for part fabrication, such as ultrasonic welding, which provides a clean and robust joining method for plastic parts. The colored liquid (3.6) visually indicates torque through liquid level display, removing the need for screens or complex tools. With this, insufficient tightening can be prevented by ensuring proper torque is applied.

[0052] This invention has the potential to revolutionize fastener technology with its wide range of applications. It can be used in automotive, construction, mechanical, and infrastructure applications. Its ease of use, affordability, and user-friendly nature make it a valuable contribution to smart fastener technology.

Claims

CLAIMS1. A method for indicating the tightening level of a fastener to the user during installation based on the increasing torque level applied, characterized by the following features:- calibration of the displacement rate of the colored fluid (3.6) based on the relationship between the applied torque and the movement of the shaft (3.3),- sequential placement of a reflector (3.7), the pre-calibrated colored fluid (3.6), an o-ring (3.5), and a shaft cap (3.4) inside an opaque body (3.1 ), followed by the joining of the opaque body (3.1 ) and the lower body (3.2) using microsonic plastic welding,- inserting the shaft (3.3) underneath the assembled set from the previous step, applying pressure to the mechanism with a hydraulic press, and embedding it into the fastener by holding the fastener with a fixture,- placing the fastener at the designated location and starting the tightening process using a wrench on the head (1 ),- as the user tightens the fastener with the wrench, the shaft (3.3) is forced downward inside the shaft cap (3.4) due to the increasing stress on the fastener body (2),- the downward movement of the shaft (3.3) causes the o-ring (3.5) to begin releasing the colored fluid (3.6) into the reflector (3.7),- the level of the colored fluid (3.6) becomes visible to the user through the reflector (3.7).

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