Force-Multiplier Torque Feedback for Accurate Electric Tool Control
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Solution Overview
Problem
Existing electric tools with force multipliers face errors due to manufacturing and long-term use, necessitating a torque tester to correct these errors to prevent over-tightening or over-loosening of objects, and current systems do not efficiently integrate torque data for precise control.
Innovation Solution
An electric-tool-torque control system that includes a torque tester, force-multiplier structure, and electric tool, utilizing a detection shaft, communication module, and storage unit to detect, store, and transmit torque data for precise rotation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a force multiplier is used to increase torque output, then the torque output capability is improved, but manufacturing errors and usage errors cause torque inaccuracy
Solution Approach 1:
The system incorporates a torque tester that continuously detects the actual torque output of the force multiplier and feeds this information back to the control circuit. The control circuit compares the detected torque with the target torque and adjusts the electric tool's output accordingly, creating a closed-loop feedback system that maintains accurate torque control despite manufacturing errors or wear in the force multiplier components
Solution Approach 2:
The patent replaces reliance on purely mechanical torque multiplication with an electronically controlled system. Instead of depending solely on the mechanical gear ratio of the force multiplier, the system uses an electric tool with a control circuit that electronically adjusts the input torque based on real-time feedback from the torque tester, substituting mechanical precision requirements with electronic control
2Measurement precision
If torque testing and error correction are implemented, then torque accuracy is improved, but system complexity increases
Solution Approach 1:
The patent merges the torque testing function, data storage, and torque control functions into a single integrated system. The torque tester, control circuit, and electric tool work as a unified system where the torque tester detects torque, the control circuit processes the data and stores correction values, and the electric tool applies corrections. This integration reduces the need for separate standalone testing and adjustment procedures
Solution Approach 2:
The system implements self-service through automated torque detection and correction. The torque tester automatically detects the force multiplier's torque characteristics, the control circuit automatically calculates correction values based on detected errors, and the electric tool automatically applies these corrections during operation. This eliminates the need for manual torque calibration and adjustment by operators
3Measurement precision
If the electric tool continuously adjusts torque based on detected data, then torque control precision is improved, but energy consumption increases
Solution Approach 1:
The system performs preliminary torque detection and error correction setup before actual work begins. The torque tester detects the force multiplier's characteristics once, the control circuit stores the correction data, and this preliminary calibration enables accurate torque control throughout operation without requiring continuous active adjustment, thereby reducing ongoing energy consumption
Data Source
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AI summary
An electric-tool-torque control system (1) includes a torque tester (10), a force-multiplier structure (20), and an electric tool (30). The torque tester (10) includes a detection shaft (102) and a communication module (103). The force-multiplier structure (20) includes a force-output end (201), a force-input end (203), a signal transmission unit (204), and a storage unit (205). The electric tool (30) includes a force-output terminal (301), a control circuit (30a), and a signal transmission module (303). The signal transmission module (303) is electrically connected to the control circuit (30a). The force-multiplier structure (20) is assembled onto the torque tester (10). A test data (105) is transmitted to the signal transmission unit (204) through the communication module (103), and is transmitted from the signal transmission unit (204) to the storage unit (205) for storage. The signal transmission unit (204) transmits the test data (105) to the signal transmission module (303). The signal transmission module (303) transmits the test data (105) to the control circuit (30a). The control circuit (30a) drives the force-multiplier structure (20) to rotate based on the test data (105).