Dynamometric Wrench Torque Angle Sensor Breakaway Detection
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Solution Overview
Problem
Existing dynamometric wrenches for quality control of screwed-in joints are operator-dependent and prone to applying excessive over-torque due to variability in measurement techniques and timing, leading to inconsistent results.
Innovation Solution
A system integrated with a dynamometric wrench that uses sensors for torque and rotation angle data, processed in real-time by a processing unit to detect the breakaway point, thereby determining residual torque independently of operator expertise and experience, using methods such as moving average and linear regression to identify the point where static friction ends and dynamic movement begins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual torque application by operator is used, then measurement capability is achieved, but measurement precision deteriorates due to operator dependency and variability in application speed and timing
Solution Approach 1:
The patent replaces manual mechanical torque application with an automated dynamometric wrench system that electronically controls torque application. The system uses a motor-driven mechanism to apply torque at controlled speeds, eliminating operator variability. Sensors measure torque and rotation angle continuously, and a processing unit automatically identifies the breakaway point through algorithmic analysis of the torque curve, replacing subjective manual assessment with objective automated measurement.
Solution Approach 2:
The system performs self-measurement by automatically detecting the breakaway point through its own sensors and processing unit. The dynamometric wrench autonomously identifies when static friction ends and dynamic movement begins by analyzing its own torque curve data, without requiring external operator interpretation. This self-service capability ensures consistent measurement criteria are always applied.
2Strength
If excessive tightening is applied to ensure joint security, then joint strength is improved, but manufacturing precision deteriorates due to over-torque damage
Solution Approach 1:
The system continuously monitors torque and rotation angle during tightening and provides real-time feedback to determine when the breakaway point is reached. The processing unit analyzes the torque curve and automatically identifies the transition from static to dynamic friction, providing precise feedback on when to stop tightening. This prevents over-torquing while ensuring adequate joint strength, as the system stops exactly at the breakaway point rather than applying excessive torque.
Solution Approach 2:
The system dynamically adjusts the tightening process by continuously monitoring the torque curve and automatically detecting changes in friction characteristics. Rather than applying a fixed predetermined torque, the system adapts to the actual mechanical behavior of the joint being tightened, identifying the unique breakaway point for each joint configuration. This dynamic approach ensures optimal tightening for each specific joint without damage.
3Productivity
If automated torque application is implemented, then productivity is improved, but device complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The dynamometric wrench is designed as a multi-functional device that combines torque application, torque measurement, rotation angle measurement, and automated breakaway point detection in a single instrument. The processing unit performs multiple functions including data acquisition from sensors, torque curve generation, breakaway point identification, and control signal generation. This universal design consolidates what could be multiple separate devices into one integrated system, managing complexity while maintaining high productivity.
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 real-time detection of residual torque, preventing excessive tightening and ensuring consistent quality control of screwed-in joints, regardless of operator skill or test conditions.
Implementation Method 1
the sensor means (7) of the rotation angle are of the gyroscope type (8) and are suitable for supplying an output signal corresponding to the rotation angle of the lever body (2)
Data Source
AI summary
The present invention refers to a system for the quality control of screwed-in joints, where the system has:a dynamometric wrench having a lever body provided, at one end, with a handle and, at the opposite end, with a coupling head having a sensor for detecting the torque applied to the threaded tightening element and a sensor for detecting the rotation angle of the lever body,a first interface anda processing unitwherein the processing unit is capable of detecting, torque and a corresponding rotation angle of the lever body.