Fluorescent Sensor Fastener Torque Monitoring
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Solution Overview
Problem
Existing fastening systems, such as torque wrenches, fail to accurately indicate when a bolt is improperly seated or if it has been over-tightened, and require mechanical engagement for torque testing, leading to inefficiencies and potential damage.
Innovation Solution
Incorporating a sensor with fluorescent dye embedded in a polymer that emits a photo-luminescent signal when a predetermined torque level is reached, allowing for non-invasive monitoring of torque levels through a detector, enabling the system to indicate under-tightening, appropriate tightening, and over-tightening conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque wrench is used to test a fastener, then torque level can be measured, but mechanical engagement is required which increases testing time and may cause damage
Solution Approach 1:
The patent replaces mechanical torque testing with optical sensing. A fluorescent sensor embedded in the fastener head emits light signals that change based on the torque applied, allowing non-contact measurement of torque levels through optical detection rather than mechanical engagement.
Solution Approach 2:
The patent creates an optical copy or representation of the mechanical torque state through fluorescent emission. The sensor converts mechanical stress into optical signals that represent the torque level, enabling measurement without physical contact.
2Measurement precision
If a torque wrench is used to check a previously tightened fastener, then torque verification is possible, but the wrench cannot determine if the fastener has been torqued past the predetermined level without increasing the torque setting which would cause further damage
Solution Approach 1:
The patent implements feedback through the fluorescent sensor that continuously monitors torque levels and provides real-time optical feedback about the fastener's torque state. The sensor can indicate whether the fastener is under-tightened, properly torqued, or over-tightened without requiring additional torque application.
Solution Approach 2:
The sensor is pre-configured with a predetermined torque threshold. When the applied torque reaches this threshold, the sensor automatically changes its optical emission to indicate the correct torque level has been achieved, providing advance warning before over-tightening occurs.
3Measurement precision
If a torque wrench is used to test fasteners, then torque measurement is achieved, but mechanical engagement results in significant torque testing times
Solution Approach 1:
The patent replaces the mechanical torque wrench system with an optical sensing system. The fluorescent sensor embedded in the fastener provides torque information through light emission that can be detected remotely, eliminating the need for mechanical engagement and significantly reducing testing time.
4Ease of operation
If existing fastening systems are used, then fastening can be performed, but there is no indication when a bolt is improperly seated or if it has been over-tightened
Solution Approach 1:
The patent uses color changes in fluorescent emission to communicate torque status information. The sensor's optical emission changes characteristics (intensity, wavelength, or pattern) to visually indicate different torque states such as under-tightened, properly torqued, or over-tightened, providing immediate visual feedback to the operator.
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
This solution allows for accurate and efficient monitoring of torque levels without mechanical engagement, preventing damage and ensuring proper fastening by providing visual or optical feedback on the torque applied to the fastener.
Implementation Method 1
a sensor comprising a fluorescent dye embedded in a polymer. The fluorescent dye may have a property that changes as a function of force applied to the first member for emission of a first photo-luminescent signal to a detector
Data Source
AI summary
A fastening device may include a first member configured for forceful engagement with a second member. The first member may include a sensor configured to emit at least a first photo-luminescent signal to a detector when at least a predetermined first torque level is applied to the first member when the first and second members are engaged.