Flange Bolt Tightening Carrier Using Sensorless Travel Positioning
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Solution Overview
Problem
The existing device for tightening screw connections in wind turbine flange connections requires complex and costly sensor technology to accurately position the tool, which can be unreliable due to interference from non-screw connection structures, leading to inefficient movement and potential errors in identifying the next screw connection to be tightened.
Innovation Solution
The control unit incorporates a travel control module that uses predefined travel lengths to move the tool carrier to the next working position without relying on position sensors, utilizing known geometrical arrangements of screw connections to calculate positions and sequence the tightening process, allowing for reliable and efficient movement and tightening of screw connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position sensor technology is used to detect screw connection structures, then the tool can be positioned accurately, but the device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the positioning function from complex sensor technology and implements it through a simplified travel control module that calculates positions based on predefined travel lengths and geometrical relationships, eliminating the need for expensive position sensors while maintaining positioning accuracy
Solution Approach 2:
The system uses its own travel control signals and predefined geometrical data to determine tool positions, rather than relying on external sensor input. The travel controller internally calculates positions based on accumulated travel lengths, making the system self-sufficient and independent of complex sensing infrastructure
2Measurement precision
If position sensors are used to identify screw connections, then positioning can be achieved, but reliability decreases due to interference from non-screw connection structures
Solution Approach 1:
The patent removes the vulnerable sensor-based identification system and replaces it with a calculation-based approach that uses predefined travel lengths and geometrical relationships to identify screw connection positions, eliminating susceptibility to sensor interference from non-screw structures
Solution Approach 2:
The travel control module acts as an intermediary that translates predefined geometrical data and travel distances into accurate tool positioning, serving as a reliable mediator between the control system and the physical tightening operation without being affected by environmental interference
3Ease of operation
If complex sensor evaluation and control technology are used, then positioning can be achieved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the essential positioning function from complex control technology and implements it through a simplified travel controller that uses basic arithmetic accumulation of travel lengths, maintaining automated operation while dramatically reducing control system complexity
Solution Approach 2:
The system uses predefined geometrical copies or models of the flange connection structure to calculate real-world positions, replacing the need for real-time sensor evaluation with pre-programmed geometrical relationships that simplify the control logic
Data Source
AI summary
A device for tightening a screw connection on a flange connection is provided with a tool carrier movable along the flange connection and provided with a traction drive. A tool is arranged on the tool carrier for tightening the screw connection and rotating the nut relative to the flange connection. A control unit is provided for moving the tool carrier in longitudinal direction of the tool carrier into a working position by traction drive control signals. In the working position, the tool is opposite the screw connection to be tightened. The control unit performs, by tool control signals, tightening of the screw connection and rotating of the nut. The control unit has a travel control module with travel controller for moving the tool carrier into the working position. The travel controller stops the traction drive after a predefined travel length has been reached that is a target variable.