Externally Adjustable Nutrunner Clutch With Inductive Slip Sensing
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Solution Overview
Problem
Existing nutrunner tools struggle to consistently and repeatably tighten fasteners to a desired torque setting, often leading to over-tightening or under-tightening, which can damage components or compromise assembly quality.
Innovation Solution
A nutrunner tool with a clutch mechanism featuring two opposing gears and a spring-biased clutch system that slips at a predefined torque threshold, combined with an inductive clutch slip sensor to detect axial position and adjust torque settings, allowing for precise torque control and automatic shut-off when the threshold is exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a clutch mechanism is added to control torque, then torque consistency is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical torque sensing mechanisms with a magnetic field-based detection system. A magnet is attached to the clutch plate, and a magnetic sensor on the PCB detects the magnet's position to determine clutch engagement and slip events, eliminating the need for complex mechanical torque measurement components.
Solution Approach 2:
The patent introduces a magnet as an intermediary element between the moving clutch plate and the stationary magnetic sensor. This magnet serves as a mediator that transfers positional information from the clutch mechanism to the control system without requiring direct mechanical contact or complex sensing mechanisms.
2Measurement precision
If an inductive sensor is used to detect clutch slip, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces potential complex mechanical or capacitive sensing mechanisms with a simple magnetic field-based detection system. The inductive sensor detects changes in magnetic field caused by the magnet's movement, providing precise clutch slip detection through electrical rather than mechanical means.
Solution Approach 2:
The patent creates a magnetic field copy or representation of the clutch plate's physical position. The magnet attached to the clutch plate generates a magnetic field that replicates the clutch's operational state, which the magnetic sensor then detects to determine clutch engagement and slip events without direct mechanical contact.
3Adaptability or versatility
If external adjuster is added for torque setting, then adaptability is improved, but ease of operation worsens
Solution Approach 1:
The patent moves the torque adjustment mechanism from the internal clutch assembly to the external housing surface. The adjuster knob is positioned on the outer housing, allowing users to modify torque settings by rotating the knob externally, which then translates to internal clutch spring compression without requiring disassembly or complex internal adjustments.
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
Ensures consistent and repeatable torque application, preventing over-tightening and under-tightening, enhancing assembly precision and reducing component damage.
Implementation Method 1
a clutch slip sensor configured to detect an axial position of the driven plate, wherein the clutch slip sensor includes an inductive sensor
Data Source
AI summary
A nutrunner includes a housing, a motor within the housing and including an output shaft rotatable about a first axis, a head extending from the housing and including an output drive that is rotatable about a second axis, and a transmission configured to transfer rotation from the output shaft to the output drive, the transmission including a drive plate that is rotatable about the first axis with respect to the housing. The nutrunner also includes a clutch mechanism having a driven plate coupled with the drive plate via a plurality of output bearings configured such that, when a torque applied to the driven plate is greater than or equal to a torque threshold, the output bearings slip and torque transfer from the drive plate to the driven plate is interrupted. A clutch slip sensor is configured to detect an axial position of the driven plate and includes an inductive sensor.