Coaxial Fastener Tightening With Z Washers to Minimize Thread Galling
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Solution Overview
Problem
Industrial bolting applications face challenges with existing tools that suffer from side load and thread galling due to corrosion, irregularities in threads, and the need for high torque to loosen corroded fasteners, which can lead to tool failure and damage to fasteners.
Innovation Solution
The HYTORC Z System, which includes multi-speed/multi-torque mode tools with torque multiplication and vibration mechanisms, uses Z Washers with friction coefficient increasing treatment means and dual drive coaxial action and reaction sockets to minimize side loads and thread galling, allowing for efficient tightening and loosening of industrial fasteners without external reaction abutments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high torque is applied to loosen corroded fasteners, then the fastener can be loosened, but side load and thread galling occur leading to tool failure and fastener damage
Solution Approach 1:
The tool is divided into multiple functional segments: a reaction arm for applying counter-torque, a drive mechanism for torque multiplication, and a fastener engagement interface. This segmentation allows each component to handle specific forces independently, preventing force concentration that causes side load and galling.
Solution Approach 2:
The reaction arm provides a counterbalancing force that opposes the torque applied to the fastener. By positioning the reaction arm to create a moment arm, the system balances the high torque forces, preventing side loads from transferring to the fastener threads and reducing galling.
2Power
If reaction arms are used to apply high torque, then torque can be multiplied, but the tool complexity increases and requires external abutments
Solution Approach 1:
The reaction arm is designed to serve multiple functions: it provides torque multiplication, acts as a structural support element, and defines the operational envelope of the tool. This multi-functionality reduces the need for separate components, simplifying the overall tool structure despite the high torque capabilities.
Solution Approach 2:
The tool incorporates adjustable reaction arm positioning that allows the operator to optimize the moment arm length based on the specific fastener and torque requirements. This dynamic adjustability enables torque multiplication without requiring a fixed complex structure, adapting the tool complexity to the actual workload.
3Reliability
If vibration mechanisms are added to reduce thread galling, then fastener loosening improves, but device complexity increases
Solution Approach 1:
The tool incorporates a vibration mechanism that generates high-frequency oscillations at the fastener interface. This vibration reduces the friction and adhesion between corroded threads, preventing galling during the loosening process. The vibration is applied locally through the fastener engagement interface, minimizing the need for additional complex components.
Solution Approach 2:
The vibration mechanism operates in periodic cycles, applying vibrational energy during the critical phases of fastener engagement and loosening. This periodic action is synchronized with the torque application, creating a combined effect that reduces galling without requiring continuous vibration, thereby reducing overall system complexity.
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 HYTORC Z System enables faster, safer, and more precise bolting operations by minimizing side loads and thread galling, reducing operator vibration, and allowing for high torque applications without reaction arms, thus improving joint reliability and reducing maintenance costs.
Implementation Method 1
Z Washers with friction coefficient increasing treatment means
Implementation Method 2
vibration mechanisms
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 intermittent (impact, vibration, ultrasonic, etc.) mechanism, 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® Z® 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®-Squirter® Washers; Z®-DTI Washers; HYTORC® Z® Washer and Nut Assemblies; Anti-Loosening Z® Washers; and any combinations thereof. Further disclosures include: Tapered Fastener Assemblies; Tapered Torsional Couplings; Two-Part Tapered Nut Assemblies; Two-Part Tapered Thread Nut Assemblies; HYTORC® Anti-Loosening Z® Washers, Nuts and SMARTSTUDS; and any combinations thereof.