High Torque Tool Dual-Trigger Safety and Precision Control
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Solution Overview
Problem
Existing systems for tightening large fasteners face challenges in accurately measuring and applying torque and angle of rotation independently of temperature and ambient conditions, while ensuring operator safety and maintaining precision as the system wears, especially in applications like wind turbines, shipbuilding, and construction.
Innovation Solution
A U-shaped high torque tool with a drive motor, reduction gear system, and dual handles with triggers that require both hands to activate, incorporating a controller and transducer for precise torque and rotation measurement, and a closed-loop system to prevent accidental activation, ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If transducerized closed loop systems are used to accurately measure and apply torque, then measurement precision and control accuracy are improved, but device complexity increases due to integral transducers, circuit boards, and controllers
Solution Approach 1:
The patent implements a closed-loop control system where transducers measure actual torque and rotation, the controller compares these measurements against target values, and the motor adjusts its output in real-time to achieve precise fastener tightening. This feedback mechanism enables accurate torque control despite the added system complexity.
2Force
If the tool is designed to withstand increasing forces for larger fasteners, then fastening capability is improved, but operator safety risks worsen due to higher potential injury from uncontrolled high torque
Solution Approach 1:
The controller is programmed with predetermined torque targets and monitoring thresholds before operation begins. The system proactively prevents harmful outcomes by shutting down the motor if torque exceeds safe limits or if the fastener becomes stuck, thereby counteracting potential injury risks before they materialize.
Solution Approach 2:
Real-time torque measurement feedback allows the controller to monitor the fastening process continuously and intervene immediately if abnormal conditions arise, such as excessive torque application or unexpected resistance, thereby protecting the operator from injury.
3Adaptability or versatility
If the system operates in varying temperature and ambient conditions, then environmental adaptability is improved, but measurement precision deteriorates due to temperature effects on transducers and electronics
Solution Approach 1:
The controller compensates for temperature effects by adjusting measurement parameters and calibration values based on detected environmental conditions. This allows the system to maintain accurate torque measurements across varying temperatures by dynamically adapting its operational parameters.
4Force
If the tool provides high torque output for large fasteners, then fastening capability is improved, but ease of operation worsens due to the physical strength required to control and operate the tool
Solution Approach 1:
The controller automatically manages the high torque output by precisely controlling motor activation and shutdown based on achieved torque targets. This eliminates the need for the operator to manually modulate high forces, allowing even operators with limited strength to safely control the tool.
Solution Approach 2:
Real-time torque feedback enables the controller to automatically adjust motor output to match the exact torque required, removing the burden of force control from the operator while maintaining precise fastening capability.
Data Source
AI summary
An apparatus for precisely measuring and applying torque and angle of rotation to tighten screwed fasteners. The apparatus includes a drive motor for generating a rotation, a pair of spaced triggers for activating the operation of the drive motor, and a controller for precisely measuring the torque to be applied and angle of rotation to be achieved by the apparatus, the controller not permitting the motor to be activated without both of the triggers being activated. A reduction gear system is also provided for reducing a rate of rotation generated by the motor, the reduction gear system outputting a rotational drive torque for driving the screwed fastener.