Coaxial Fastener Tightening With Vibration to Reduce Thread Galling
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Solution Overview
Problem
Industrial bolting applications face challenges with side load and thread galling due to friction and adhesion between metallic surfaces, leading to material wear and corrosion, especially in high load, low speed conditions, where existing tools struggle to efficiently tighten or loosen fasteners without causing damage.
Innovation Solution
The HYTORC Z System employs multi-speed/multi-torque mode tools with torque multiplication and vibration mechanisms, using Z Washers with friction coefficient increasing treatment means and dual drive coaxial action and reaction sockets to minimize side loads and galling, allowing for efficient and precise bolt tightening and loosening without external reaction abutments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional torque tools are used to tighten threaded fasteners, then fastening operation can be performed, but side load and thread galling occur due to friction and adhesion between metallic surfaces
Solution Approach 1:
The patent applies ultrasonic vibration to the fastener during tightening operations. The vibration mechanism generates high-frequency oscillations that reduce friction and adhesion between metallic surfaces, preventing thread galling and reducing side loads while maintaining fastening reliability.
Solution Approach 2:
The patent employs intermittent or periodic tightening cycles with alternating vibration and static torque application. This periodic action allows the fastener to be tightened in stages, with vibration applied during high-resistance phases to prevent galling while maintaining progress toward the target torque.
2Strength
If high torque is applied to tighten fasteners in high load conditions, then fastening strength is achieved, but material wear and corrosion increase due to friction and adhesion
Solution Approach 1:
Ultrasonic vibration is applied during the tightening process to reduce friction and adhesion between metallic surfaces. This prevents material wear and corrosion while still achieving the required fastening strength by allowing smooth thread engagement even under high load conditions.
Solution Approach 2:
The patent changes the physical state and surface properties of the fastener through vibration-induced parameter changes. The high-frequency vibration alters friction coefficients and surface interaction characteristics, reducing material wear and corrosion while maintaining the necessary clamping force and fastening strength.
3Productivity
If existing tools are used to tighten or loosen fasteners, then basic fastening operation is performed, but tool and fastener failure risk increases due to thread galling and material wear
Solution Approach 1:
The integration of ultrasonic vibration into the fastening tool prevents thread galling and material wear during both tightening and loosening operations. This extends the service life of both the tool and fastener while maintaining high productivity through efficient fastening operations.
Solution Approach 2:
The vibration mechanism enables the fastening system to protect itself from wear and galling during operation. The ultrasonic vibration continuously reduces friction and prevents adhesion between surfaces, allowing the tool and fastener to serve themselves by preventing their own degradation throughout the fastening process.
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
The system enables faster, safer, and more reliable bolting operations by minimizing side loads and thread galling, maintaining even torque load and joint compression, and reducing the risk of tool and fastener failure, while simplifying tool use and reducing operator exposure to vibration.
Implementation Method 1
at least one vibration force mechanism including a vibration transmitter for an intermittent force mode
Implementation Method 2
a turning force multiplication mechanism in a housing including a turning force multiplication transmitter for all torque modes from lower resistance to higher resistance
Implementation Method 3
Z Washers with friction coefficient increasing treatment means
Data Source
AI summary
This application seeks to protect Applicant's HYTORC® Z® System which involves: tools having multi-speed/multi-torque modes with torque multiplication and vibration mechanisms without use of external reaction abutments; a force transfer means to yield in-line co-axial action and reaction for use with such tools; driving means and shifting means capable of attaching to washers under the nut for use with such tools and force transfer means; associated washers and fasteners for use with such tools, force transfer means and driving means; and related accessories for use with such tools, force transfer means, driving means, washers and fasteners.The HYTORC® Z® System includes the following: Z® Washers located under nuts or bolt heads of various types having engageable perimeters of multiple shapes, sizes, geometries and serrations, such as washer/fastener radius engagement differentials, and frictionally biased faces with relatively higher friction against the flange surface and relatively lower friction against the nut, such as friction coefficient increasing treatment means of various types, sizes and locations; HYTORC Z® Guns incorporating a powerful impact mechanism and a precise torque multiplier in the same tool combining rapid run-down with calibrated torque; HYTORC® Z® Sockets with dual drive coaxial action and reaction having outer sleeves to react on Z® Washers and an inner sleeves to turn nuts or bolt heads; HYTORC® ZR Spline Adapters and Reaction Plates for backwards compatibility with HYTORC®'s torque/tension systems including the AVANTI® and ICE® square drive systems, the STEALTH® limited clearance system, the pneumatic jGUN® series, the FLASH® Gun and LITHIUM Series electric multipliers and more; the combination of HYTORC® Z® Washer and the HYTORC® Z® Dual Friction Washer™ including a dual friction-enhanced face washer and/or the HYTORC® Z® Nut/Bolt for counter-torque under a nut or bolt head on the other side of the joint; HYTORC® Z® Dual Drive Offset Links for tight clearances while using HYTORC®'s torque/tension systems; HYTORC® Z® Vibration Mechanisms applied thereof; Z®-Direct Tension Indicating Washers; HYTORC® Z® Washer and Nut Assemblies; and any combinations thereof. Further disclosures include: Tapered Fastener Assemblies; Tapered Torsional Couplings; Two-Part Tapered Nut Assemblies; and Two-Part Tapered Thread Nut Assemblies.