Impact Driver Torque Sequencing for Multi-Connector Strain Control
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Solution Overview
Problem
Existing power tools face challenges in compensating for changes in strain during multiple connector fastening operations, leading to inconsistent torque application and potential damage to components.
Innovation Solution
A controller in the power tool determines individual desired torque values for each connector based on the overall desired torque value and the sequence of connectors, ensuring that the first connector receives a higher torque than subsequent ones, and adjusts the tool's output to achieve the desired torque for each connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single torque value is applied to all connectors in a fastening operation, then the fastening process is simple to control, but the strain distribution becomes inconsistent leading to potential damage or improper fastening
Solution Approach 1:
The patent segments the fastening operation into multiple sequential steps, with each step targeting a specific connector. The controller divides the overall fastening task into individual connector operations, assigning a unique torque value to each connector based on its position and the strain it experiences. This segmentation allows precise torque control for each connector while maintaining overall system manageability.
Solution Approach 2:
The patent implements dynamic torque adjustment where the torque value changes based on the current step in the fastening sequence and the specific connector being tightened. The controller dynamically modifies torque parameters for each connector rather than applying a static torque value, adapting to the changing strain conditions as each connector is secured.
2Strength
If higher torque is applied to ensure adequate fastening, then connection strength is improved, but component damage may occur due to overtightening
Solution Approach 1:
The patent applies local quality by assigning different torque values to different connectors based on their specific positions and the strain they experience. Each connector receives a customized torque value tailored to its local conditions, ensuring adequate fastening strength where needed while preventing overtightening damage in other areas. This localized torque optimization balances connection strength with component protection.
3Reliability
If torque is increased for subsequent connectors to compensate for strain reduction, then overall fastening integrity is improved, but the risk of overtightening earlier connectors increases
Solution Approach 1:
The patent implements preliminary action by pre-calculating and pre-setting the appropriate torque value for each connector before the fastening operation begins. The controller stores a sequence of torque values corresponding to each connector in advance, eliminating the need for real-time torque adjustments during operation. This preliminary planning ensures precise torque control for each connector while maintaining overall fastening integrity.
Data Source
AI summary
An impact driver comprising a controller. The controller is configured to receive a number of connectors and, for each connector of a plurality of connectors equal to the number of connectors, determine, based on the number of connectors, a torque for the connector, wherein, when the connector is a connector other than a final connector tightened, the determined torque is associated with a level of strain greater than a desired level of strain, and tighten the connector using the torque determined for the connector.