Aircraft Fastener Torque Management via Sensor Feedback
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Solution Overview
Problem
The high cost and inefficiency of aircraft assembly due to the need for dual operator supervision in screw tightening operations, which is impractical for large-scale aircraft assembly and increases labor costs.
Innovation Solution
A fastening part tightening management system that includes a manual torque wrench for setting and detecting tightening torque, a marking pen for confirming operation completion, and an information terminal for determining and notifying the operator of the tightening state, allowing single-operator reliable screw tightening without supervision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manual torque wrench is used with dual operator supervision in aircraft assembly, then the reliability of screw tightening is improved, but the labor cost and assembly time increase significantly
Solution Approach 1:
The system incorporates a torque sensor that detects the tightening torque in real-time and transmits this data to a supervisor terminal. The supervisor can monitor the actual torque applied and provide feedback to the operator, enabling quality control without requiring physical presence at each tightening location. This resolves the contradiction by maintaining reliability through automated feedback mechanisms while improving productivity by eliminating the need for dual operator supervision.
Solution Approach 2:
The patent replaces the mechanical supervision system (where a supervisor physically observes and confirms each tightening action) with an electronic monitoring system using torque sensors and wireless communication. This substitution allows the tightening operation to be monitored and verified automatically, maintaining reliability while significantly reducing labor requirements and assembly time.
2Manufacturing precision
If an electric torque wrench is used in aircraft assembly, then the tightening precision is improved, but the device cannot be practically deployed due to the large work area and high ceiling
Solution Approach 1:
The patent replaces the electric torque wrench with a manual torque wrench equipped with a torque sensor. This substitution maintains the precision measurement capability while adapting to the aircraft assembly environment where electric wrenches cannot be suspended from the ceiling. The manual wrench can be freely moved throughout the large work area while the sensor continues to provide accurate torque data wirelessly.
Solution Approach 2:
The system design makes the torque monitoring capability universal by using wireless communication between the torque sensor and supervisor terminal. This allows the same monitoring system to work with manual torque wrenches throughout the entire aircraft assembly area, regardless of location or ceiling height, providing both precision measurement and broad adaptability.
3Reliability
If dual operator supervision is implemented for screw tightening, then the quality control is improved, but the employment cost doubles
Solution Approach 1:
The system uses automated feedback through torque sensors and supervisor terminals to replace the need for a second operator. The sensor continuously monitors tightening torque and transmits this information to the supervisor, who can verify quality remotely. This maintains quality control while reducing the workforce from two operators to one, directly addressing the cost issue.
Solution Approach 2:
The torque sensor performs self-monitoring of the tightening operation and automatically transmits data to the supervisor terminal. This self-service capability eliminates the need for human supervision at each tightening location, allowing one operator to perform quality-verified work independently while maintaining high reliability standards.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable single-operator screw tightening operations, reducing aircraft assembly costs by ensuring proper torque application and completion confirmation without the need for dual supervision.
Implementation Method 1
a manual torque wrench that tightens a fastening part up to a set torque while activating a tightening torque and detects and transmits tightening torque information acting on the fastening part
Implementation Method 2
a marking pen that performs marking to the fastening part, the tightening operation of which is ended by the manual torque wrench, detects the marking operation, and transmits marking completion information
Data Source
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AI summary
A fastening part tightening management system (1) that manages a tightening state of a fastening part such as a screw to fix a constituent part of an aircraft in an aircraft assembling process includes a manual torque wrench (2) that tightens a fastening part up to a set torque while activating a tightening torque and detects and transmits tightening torque information acting on the fastening part, a marking pen (3) that performs marking to the fastening part, the tightening operation of which is ended by the manual torque wrench (2), detects a writing pressure in the marking, and transmits marking completion information; an information processing device (5) that determines a tightening state of the fastening part based on the tightening torque information and the marking completion information, and a mobile information terminal (4) that notifies an operator of a determination result obtained by the information processing device (5).