Force-Multiplier Torque Calibration for Electric Tool Accuracy
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Solution Overview
Problem
Existing electric tools with force multipliers face errors due to manufacturing inaccuracies and long-term use, necessitating a torque tester to correct these errors to prevent over-tightening or loosening of objects, which can cause breakage or collapse.
Innovation Solution
An electric-tool-torque control system that integrates a torque tester, force-multiplier structure, and an electric tool, utilizing a detection shaft, communication module, and storage unit to detect, store, and transmit torque data for precise rotation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a force multiplier is used to increase torque output, then the torque output capability is improved, but manufacturing errors and usage wear cause torque accuracy to deteriorate
Solution Approach 1:
The system performs preliminary detection of the force multiplier's actual torque characteristics using a torque tester before actual operation. The detected data is stored in advance, and the control system uses this pre-acquired information to compensate for manufacturing errors and usage wear, ensuring accurate torque control from the start of operation.
Solution Approach 2:
The system implements a feedback mechanism where the torque tester continuously or periodically detects the actual torque output of the force multiplier. The control system receives this feedback data, compares it with the target torque, and automatically adjusts the electric tool's output to compensate for manufacturing errors and usage wear, maintaining accurate torque control throughout the force multiplier's service life.
2Measurement precision
If torque compensation for errors is implemented, then torque control accuracy is improved, but the system complexity increases
Solution Approach 1:
The system merges the torque tester, data storage unit, and control system into an integrated torque control system. The torque tester, force multiplier, and electric tool are connected through a unified communication interface, allowing detection, storage, and control functions to work together seamlessly. This integration reduces the need for separate independent systems and simplifies the overall structure while maintaining high torque control accuracy.
Solution Approach 2:
The system enables the force multiplier to self-diagnose and self-compensate for its own manufacturing errors and usage wear. The torque tester automatically detects the force multiplier's actual characteristics, the storage unit saves this data, and the control system automatically applies compensation without requiring manual intervention or complex external calibration equipment, thereby reducing system complexity.
3Measurement precision
If a torque tester is integrated with the force multiplier, then error detection capability is improved, but the device complexity and cost increase
Solution Approach 1:
The torque tester is designed with multi-functionality to serve multiple purposes: it detects the force multiplier's torque characteristics, stores the detected data, communicates with the control system, and can potentially test different force multipliers or configurations. This universal design reduces the need for multiple specialized devices and justifies the added complexity by providing comprehensive functionality that benefits the entire torque control system.
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 accurately adjusts for manufacturing and usage errors in force multipliers, ensuring consistent torque output and preventing damage by enabling precise torque control.
Implementation Method 1
The principle of the force multiplier is to generate a large output torque by inputting a smaller force through the difference of high-efficiency gear ratio.
Data Source
AI summary
An electric-tool-torque control system includes a torque tester, a force-multiplier structure, and an electric tool. The torque tester includes a detection shaft and a communication module. The force-multiplier structure includes a force-output end, a force-input end, a signal transmission unit, and a storage unit. The electric tool includes a force-output terminal, a control circuit, and a signal transmission module. The signal transmission module is electrically connected to the control circuit. The force-multiplier structure is assembled onto the torque tester. A test data is transmitted to the signal transmission unit through the communication module, and is transmitted from the signal transmission unit to the storage unit for storage. The signal transmission unit transmits the test data to the signal transmission module. The signal transmission module transmits the test data to the control circuit. The control circuit drives the force-multiplier structure to rotate based on the test data.