Contact Bridge Sensor for Loose Fastener Detection
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Solution Overview
Problem
Existing methods for detecting loose fasteners, such as nuts or bolts, often require frequent visual inspection and do not provide real-time monitoring, which can lead to delayed detection and potential machine damage.
Innovation Solution
A sensor system that includes a contact bridge with electrical conductors connected to the fastener and a stationary object, detecting changes in conductivity to determine if the fastener has moved from a tightened to a loosened position, allowing for wireless communication of the status to a central station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection methods are used to detect loose fasteners, then the detection method is simple and does not require additional sensors, but frequent manual inspection is required and real-time monitoring is not achieved
Solution Approach 1:
The patent replaces manual visual inspection with an automated sensor system that uses electrical conductivity detection. The contact bridge sensor automatically detects fastener status changes through electrical contact, eliminating the need for repeated manual visual checks and providing continuous monitoring capability.
Solution Approach 2:
The sensor system performs self-monitoring of fastener status without requiring external inspection resources. The contact bridge automatically detects when a fastener becomes loose through changes in electrical conductivity, and the system self-reports the status, freeing up operational time.
2Loss of information
If mechanical indicator systems are used to show fastener status, then the indication is visible and tactile during inspection, but the system requires manual inspection to detect the indicator position
Solution Approach 1:
The patent replaces mechanical indicator systems with an electrical sensing system. Instead of relying on physical indicators that require manual observation, the contact bridge sensor uses electrical conductivity changes to automatically detect and report fastener status, eliminating the need for manual inspection of indicator positions.
Solution Approach 2:
The patent introduces an electrical contact bridge as an intermediary between the fastener and the monitoring system. This contact bridge translates mechanical fastener status into electrical signals that can be automatically detected and transmitted, serving as a mediator that eliminates direct manual inspection requirements.
3Measurement precision
If pressure sensors are used to measure torque, then the torque measurement is direct and accurate, but the system complexity increases and requires additional sensor components
Solution Approach 1:
The patent extracts only the essential detection function needed for fastener status monitoring - detecting whether a fastener is loose or tight - rather than measuring the full spectrum of torque parameters. The contact bridge sensor provides sufficient information for safety-critical loose fastener detection without the complexity of precision torque measurement systems.
Solution Approach 2:
The patent employs a simple, low-cost contact bridge sensor that prioritizes reliability for safety detection over precision measurement capability. The sensor uses basic electrical contact principles rather than complex piezoresistive or strain gauge technology, reducing system complexity while maintaining adequate performance for loose fastener detection.
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 real-time monitoring of fastener tightness, reducing the risk of machine damage by providing immediate alerts and reducing the need for frequent visual inspections through wireless communication of the fastener's operational status.
Implementation Method 1
One of the first and second sides of the contact bridge includes first and second spaced apart electrical conductors, and the other one of the first and second sides of the contact bridge includes a third electrical conductor. When the first connecting means connects the first side of the contact bridge to the fastener for movement in response to movement of the fastener, and when the second connecting means connects the second side of the contact bridge to the object to remain stationary relative to the object, the third electrical conductor is positionable to contact the first and second electrical conductors when the fastener is in the first position, and the third electrical conductor is spaced apart from at least one of the first and second electrical conductors when the fastener is in the second position.
Data Source
AI summary
One illustrative embodiment includes an apparatus for detecting if a fastener moves from a first position to a different second position. The apparatus includes a first connector for connecting a first side of a contact bridge to the fastener for movement in response to movement of the fastener, and a second connector for connecting a second side of the contact bridge to an object to remain stationary relative to the object. One of the first and second sides of the contact bridge includes first and second spaced apart electrical conductors; the other side includes a third electrical conductor. The third electrical conductor is positionable to contact the first and second electrical conductors when the fastener is in the first position, and the third electrical conductor may be spaced apart from at least one of the first and second electrical conductors when the fastener is in the second position.