Fastening Unit Life Decision via Sensor Correlation Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tool systems lack accurate management of fastening unit life due to wear, leading to a decline in fastening torque, which can result in insufficient fastening operations.
Innovation Solution
A tool system comprising a fastening unit, a sensor unit, a storage device, and a decider that detects physical quantities during fastening operations, stores criterion information based on feature quantities, and makes decisions about the life of the fastening unit using both criterion and actually measured correlations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fastening unit is repeatedly used to perform fastening operations, then the productivity increases, but the fastening unit gradually wears down and fastening torque declines
Solution Approach 1:
The system performs preliminary actions by detecting physical quantities during fastening operations and making decisions about fastening unit life before significant wear occurs. The sensor unit continuously monitors parameters such as fastening torque, and the decider compares measured values against threshold values to predict wear and schedule maintenance proactively, preventing torque decline before it affects productivity.
2Loss of time
If the fastening unit is used until wear causes torque decline, then the loss of time is minimized, but the fastening operation becomes insufficient
Solution Approach 1:
The system implements feedback by continuously detecting physical quantities during fastening operations and using this information to make real-time decisions about fastening unit life. The sensor unit monitors parameters such as fastening torque, and the decider compares measured values against threshold values to determine when replacement is needed, ensuring fastening quality is maintained while optimizing replacement timing to minimize downtime.
3Measurement precision
If multiple feature quantities are used to make decision about life, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The system applies segmentation by dividing the decision-making process into distinct functional modules: the sensor unit for detecting physical quantities, the storage device for storing threshold values, and the decider for comparing and determining fastening unit life. This modular segmentation allows multiple feature quantities to be processed accurately while keeping each component relatively simple and manageable.
Data Source
AI summary
A tool system includes a fastening unit, a sensor unit, a storage device, and a decider. Fastening unit fastens a fastening member by driving a tip tool in rotation with motive power supplied from a motor. Sensor unit detects a physical quantity while fastening unit is performing a fastening operation on fastening member. Storage device stores criterion information. Criterion information has been set based on a criterion correlation between criterion feature quantities which are feature quantities of multiple different types and used as criteria for making a decision about life of fastening unit. Decider makes decision about life of the fastening unit in accordance with not only criterion information but also an actually measured correlation. Actually measured correlation is a correlation between actually measured feature quantities, which are feature quantities respectively corresponding to multiple different types of criterion feature quantities and are based on physical quantity detected.