Flange Bolt Tensioning With Screw Identification and Sequence Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for installing and maintaining flange connections, particularly in large structures like wind turbines, often result in fitters losing track of which screws have been tightened and in what sequence, leading to potential errors and safety risks.
Innovation Solution
A method and tool utilizing a manually movable tool equipped with a screw tensioning structure, processing unit, and screw identification sensor to ensure each screw connection is correctly identified, positioned, and tensioned in a predefined sequence, with the tool being blocked or released based on correct positioning and documentation of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple screw connections are tightened manually without tracking system, then the installation process is simple and quick, but the fitter loses track of which screws have been tightened and in what sequence
Solution Approach 1:
The system implements feedback by detecting which screw connections have been tightened and providing real-time information about the tightening status. The processing unit tracks the sequence of tightened screws and provides feedback to the operator through the user interface, ensuring accurate tracking without complicating the manual operation.
Solution Approach 2:
A control system acts as an intermediary between the manual tightening operation and the tracking requirement. This intermediary system includes sensors that detect tightening status, a processing unit that manages the tracking logic, and a user interface that presents the information, thereby mediating between simple manual operation and reliable tracking.
2Reliability
If a tracking system is implemented to monitor screw tightening sequence, then the reliability of the installation process is improved, but the device complexity increases
Solution Approach 1:
The tool system is designed with multi-functionality to reduce overall complexity. The same tool that performs the tightening operation also contains the sensors and processing units for tracking and monitoring. This universal tool eliminates the need for separate tracking devices, thereby reducing system complexity while maintaining reliable tracking.
Solution Approach 2:
The tightening tool is self-sufficient by integrating the tracking and monitoring functions directly into the tool itself. The tool automatically detects which screws have been tightened and manages the tracking sequence without requiring external monitoring equipment, thereby reducing overall system complexity.
3Productivity
If the tool is released automatically after each tightening, then the productivity increases, but the risk of incorrect sequencing increases
Solution Approach 1:
The system uses feedback control to manage the release mechanism. The processing unit continuously monitors the tightening sequence and provides feedback to the release mechanism. The tool is released only when the correct screw is identified and the sequence is verified, thereby maintaining sequence accuracy while enabling rapid productivity.
Solution Approach 2:
The manual control of tool release is replaced with an automated electronic control system. The processing unit uses electronic signals to control the release mechanism based on detected tightening status, replacing manual mechanical control with an automated system that ensures sequence accuracy while improving productivity.
Data Source
AI summary
A method for installation and/or maintenance of a flange connection includes screw connections with a manually movable tool including a screw tensioning structure, a processing unit and a screw identification sensor. The method includes assigning a one-to-one identification to each screw connection of the flange connection, determining a screw connection to be tensioned, positioning the tool on a respective screw connection to be tensioned, identifying the respective screw connection by the screw identification sensor, releasing the screw tensioning structure by the processing unit, and tensioning the respective screw connection by the screw tensioning structure. It is checked whether the tool or the screw tensioning structure is placed correctly on the screw connection. The screw tensioning structure is released when the result of this check is positive and/or the screw tensioning structure is blocked or stopped when the result of this check is negative.