Electric Bolt Tensioning Control for Faster Multi-Fastener Assembly
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Solution Overview
Problem
Existing screw tensioning devices for connecting elements are time-consuming, especially when multiple elements need to be fixed, due to the manual operation and hydraulic actuation process.
Innovation Solution
A system with electric actuators and a control unit that translates rotational movements into translational movements to tension and loosen connecting elements, utilizing a fluid chamber and piston mechanism to apply tension efficiently, and a control unit to manage the operation of multiple devices simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If manual operation and hydraulic actuation are used for tensioning connecting elements, then the tensioning force can be applied, but the assembly process becomes time-consuming
Solution Approach 1:
The patent replaces the manual hydraulic actuation system with an electric actuator system. The electric actuator directly converts electrical energy to mechanical motion, eliminating the need for manual hydraulic pump operation and fluid management. This substitution maintains the ability to generate high tensioning forces while dramatically reducing the time required for assembly operations.
Solution Approach 2:
The patent changes the actuation parameter from hydraulic pressure (requiring manual pumping) to electrical control (enabling automated operation). By using electric actuators with controlled electrical input, the system can precisely regulate the tensioning force application rate and total duration, optimizing both force generation and assembly speed. The electric actuator's ability to rapidly respond to control signals enables faster cycle times compared to manual hydraulic systems.
2Strength
If multiple connecting elements need to be fixed, then the connection strength increases, but the operation time increases significantly
Solution Approach 1:
The patent designs the electric actuator system to be universally applicable to multiple connecting elements. The same actuator can be sequentially or simultaneously applied to different bolts or connecting elements without requiring tool changes or system reconfiguration. This multi-functionality enables efficient handling of multiple fastening operations, maintaining high connection strength requirements while minimizing the cumulative time loss across multiple elements.
Solution Approach 2:
The electric actuator system enables continuous operation across multiple connecting elements without the interruptions inherent in manual hydraulic systems. The actuator can maintain consistent tensioning force and speed across all connecting elements, eliminating idle time between operations. The system can continuously cycle through multiple fastening operations, applying tension, holding, and releasing in a seamless manner that maximizes productivity while ensuring each connection achieves the required strength.
3Reliability
If hydraulic actuation is used, then the tensioning process can be controlled, but the system complexity increases
Solution Approach 1:
The patent replaces the complex hydraulic system (including fluid reservoirs, hoses, pressure regulators, and manual pumps) with a relatively simple electric actuator system. The electric actuator integrates the force generation and motion control functions into a single compact unit, eliminating numerous hydraulic components. This substitution maintains reliable tensioning control through electrical signal management while dramatically reducing overall system complexity and the potential for leaks or fluid-related failures.
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 enhances operability and enables time-efficient assembly of tensable connecting elements by automating the tensioning process, reducing manual intervention and improving assembly efficiency.
Implementation Method 1
the actuating unit is configured for manipulating a volume of the fluid chamber by translationally actuating the piston so as to move the engagement element relative to the support element
Data Source
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AI summary
The present invention refers to system (1) for tensioning at least one connecting element (12) fastened to a component (18, 20) to be tightened. The system (1) comprises at least one connecting element tensioning device (10) having an engagement element (24) connectable to the connecting element (12), and an actuating unit (44) for translating a rotational movement applied to an actuating element (46) into a translational movement of the engagement element (24) relative to the component (18, 20); at least one electric actuator (13) for rotationally actuating the actuating element (46); and a control unit (CPET) for actuating the at least one electric actuator (13).