Bolt Tightness Detection via Relative Orientation Angles
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Solution Overview
Problem
Existing methods for monitoring the tightness state of bolts and nuts are laborious, costly, and prone to errors, particularly in harsh environments, and lack the ability to provide continuous or timely detection, which can lead to severe accidents or structural failures.
Innovation Solution
The use of microelectromechanical systems (MEMS) fabricated sensors such as accelerometers, gyroscopes, and magnetic field sensors to detect the motion and orientation of bolts and nuts, and the structures they are mounted on, allowing for the calculation of screwed-out angles to determine tightness state in real-time or periodically, with low power consumption and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If stress sensors are mounted on bolts or nuts to detect tightness, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces direct stress measurement (mechanical sensing) with motion and orientation detection using accelerometers, gyroscopes, and magnetic field sensors. By measuring the movement and angular orientation of the bolt or nut relative to the structure, the system indirectly determines tightness state without requiring direct stress sensors mounted on the fastener.
Solution Approach 2:
The patent introduces motion and orientation parameters as intermediary measurements. Instead of directly measuring stress, the system measures the bolt's/nut's movement and angular position relative to the structure, using these intermediate parameters to infer the tightness state through calculation.
2Measurement precision
If ultrasonic techniques are used to detect stress change, then measurement precision is improved, but reliability deteriorates due to environmental factors
Solution Approach 1:
The patent replaces ultrasonic stress detection with motion and orientation sensing using accelerometers, gyroscopes, and magnetic field sensors. These sensors measure physical movement and angular position, which are less susceptible to environmental interference like temperature and humidity compared to ultrasonic wave propagation through the material.
3Ease of operation
If mechanical or electronic switches are installed to detect rotation, then ease of operation is improved, but measurement precision and continuous monitoring capability deteriorate
Solution Approach 1:
The patent transitions from static switch-based detection to dynamic continuous measurement using accelerometers, gyroscopes, and magnetic field sensors. These sensors continuously track motion and orientation parameters, enabling real-time monitoring of bolt/nut rotation and tightness state changes throughout operation, rather than only at discrete trigger points.
Solution Approach 2:
The patent implements continuous tightness monitoring by continuously collecting motion and orientation data from the sensors. The system processes this continuous data stream to calculate angular orientation and detect tightness state changes in real-time, providing ongoing surveillance rather than periodic or event-triggered checks.
4Measurement precision
If multiple triggering angles are configured for switch detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses dynamic continuous measurement of angular orientation through gyroscopes and magnetic field sensors, replacing the static multi-angle switch configuration. The system continuously tracks the bolt's/nut's angular position and compares it against reference values, achieving precise multi-position detection without requiring multiple physical switches or complex trigger configurations.
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
This method enables fast, reliable, and accurate detection of bolt and nut tightness with low calculation and installation costs, allowing for timely identification of loose fasteners and potential hazards, and can be configured for multi-level alarm systems.
Implementation Method 1
The tightness state of a bolt or nut may be detected using one or more sensors such as an accelerometer, a gyroscope, and/or a magnetic field sensor
Implementation Method 2
The tightness state of a bolt or nut may be detected using one or more sensors such as an accelerometer, a gyroscope, and/or a magnetic field sensor
Implementation Method 3
The tightness state of a bolt or nut may be detected using one or more sensors such as an accelerometer, a gyroscope, and/or a magnetic field sensor
Data Source
AI summary
The present invention discloses methods and systems for detecting the tightness state of a bolt or nut under inspection. At least one sensor is mounted on the bolt or nut. At least another sensor is mounted on a structure where the bolt or nut is mounted. Data of motion and/or orientation is acquired. A first angle of the bolt or nut in a plane of rotation of the bolt or nut is calculated. The first angle is related to rotation of the bolt or nut. A second angle of the structure in the plane of rotation of the bolt or nut is calculated. The second angle is unrelated to rotation of the bolt or nut. The initial angle difference between the first and second angles is calculated when the bolt or nut is tight. A subsequent angle difference between the first and second angles is calculated during the inspection. Using the initial angle difference and the subsequent angle difference, the screwed-out angle of the bolt or nut is obtained. Then, the tightness state of the bolt or nut is determined based on the screwed-out angle.