Fastener Tool Material Sensing for Error-Proof Installation
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Solution Overview
Problem
In vehicle assembly lines, visually similar fasteners made of different materials are often difficult to distinguish, leading to incorrect installation due to similar size, shape, and color, and require specific torque and speed settings, which existing tools fail to error-proof effectively.
Innovation Solution
A tooling system with sensors, such as magnetic field sensors or metallic proximity sensors, and a controller to determine the material type of fasteners, ensuring correct installation by adjusting torque and speed settings for each type of fastener.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple tools are used to install different fasteners, then installation versatility is improved, but error-proofing capability deteriorates because operators can still use wrong fasteners with correct tools
Solution Approach 1:
The system incorporates sensors that detect the material properties of the inserted fastener and provide feedback to the controller. The controller then adjusts installation parameters or prevents operation if the wrong fastener is detected, creating a closed-loop error-proofing mechanism that maintains versatility while eliminating human error
Solution Approach 2:
The patent replaces manual visual identification and operator judgment with automated sensor-based material detection. Magnetic sensors or capacitive sensors automatically identify fastener material composition, substituting the mechanical/visual inspection process with electronic detection to ensure correct fastener-tool matching
2Ease of manufacture
If fasteners are made visually similar with same size, shape, and color, then ease of manufacture is improved, but detectability deteriorates making it difficult to distinguish different fastener types
Solution Approach 1:
The system replaces visual/mechanical distinction methods with electronic sensor-based material detection. Sensors detect intrinsic material properties such as magnetic susceptibility or electrical capacitance, allowing differentiation of fasteners based on material composition rather than external appearance
Solution Approach 2:
The invention shifts the differentiation parameter from external visual characteristics (size, shape, color) to internal material properties (magnetic susceptibility, electrical capacitance). This allows fasteners to maintain identical external dimensions while being distinguishable through material composition detection
3Manufacturing precision
If different fasteners require different torque and speed settings, then installation precision is improved, but device complexity increases requiring multiple tools with adjustable parameters
Solution Approach 1:
The patent implements a universal tool platform that can accommodate different fastener types through a single interface. The tool automatically configures itself based on sensor detection, eliminating the need for multiple specialized tools while maintaining precise installation parameters for each fastener type
Solution Approach 2:
The system performs preliminary detection of fastener material properties before installation begins. The controller pre-configures appropriate torque and speed settings based on the detected fastener type, automatically preparing the optimal installation parameters before the actual fastening operation
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 reduces installation errors by accurately identifying fastener types and applying appropriate installation parameters, ensuring correct fasteners are used with the correct settings, thereby reducing warranty and repair costs.
Implementation Method 1
The tool may include a magnet that is movably disposed within the tool... configured to detect a magnetic force imparted by one of the threaded fasteners of the first fastener type
Implementation Method 2
The tool may include a spring biasing the magnet toward a first position, wherein the magnet is configured to slide toward a second position when a fastener of the first fastener type is inserted into the socket
Data Source
AI summary
Tooling systems and methods may be employed for installing a plurality of visually similar threaded fasteners to a plurality of assemblies. Each of the assemblies may have one or more threaded mating surfaces configured to receive different types of threaded fasteners, e.g., formed of different materials. The tooling system may include a tool(s) having a drive surface configured to install a threaded fastener by relative rotation of a gripping feature of the fastener with respect to a corresponding mating thread, each tool having a sensor disposed adjacent the drive surface and configured to detect a presence of the first material when a gripping feature of the one of the threaded fasteners of the first fastener type is positioned on the drive surface. The tooling system may also include a controller configured to determine the type of the selected threaded fastener based upon the sensor.