Impact Rotary Tool Torque Estimation for Adaptive Tightening Control
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Solution Overview
Problem
Rotary impact tools face challenges in accurately achieving target torque values due to variations in screw members and tightening conditions, leading to inefficiencies in torque management and increased labor in identifying optimal parameter settings.
Innovation Solution
A rotary impact tool with an impact mechanism, impact detection unit, mode setting unit, torque estimation unit, parameter setting unit, and control unit that allows for the calculation and adjustment of torque values based on detected impacts and stored work information, enabling precise torque management through customizable parameter settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque measurement means is provided in the output shaft to measure actual tightening torque directly, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary approach by using impact detection units and rotation angle sensors to indirectly measure tightening torque. Instead of directly measuring torque in the output shaft, the system detects impacts from the hammer mechanism and correlates them with rotation angles to calculate torque values, thereby achieving measurement precision without direct torque measurement equipment
Solution Approach 2:
The patent replaces the mechanical torque measurement system with a sensor-based detection and calculation system. By substituting direct mechanical torque measurement with impact detection units, rotation angle sensors, and computational processing, the system achieves torque measurement functionality without the complexity of direct torque measurement mechanisms
2Ease of operation
If the manufacturer creates a master table with predetermined shut-off impact counts for each tightening torque value, then ease of operation is improved, but adaptability to different screw members and tightening conditions deteriorates
Solution Approach 1:
The patent implements dynamics by making the shut-off impact count variable rather than fixed. The control unit dynamically adjusts the shut-off impact count based on real-time detection of impact characteristics and rotation angles during the tightening process, allowing the system to adapt to different screw members and tightening conditions while maintaining ease of operation through automated adjustment
Solution Approach 2:
The patent employs feedback mechanisms where the control unit continuously monitors impact detection unit signals and rotation angle sensor data, then adjusts the shut-off impact count accordingly. This feedback loop enables the system to adapt to different tightening conditions and screw member characteristics while maintaining simple operation for the user
3Manufacturing precision
If the control unit stops motor rotation when the calculated tightening torque reaches the target torque value, then manufacturing precision is improved, but loss of time increases due to parameter adjustment requirements
Solution Approach 1:
The patent implements self-service by enabling the control unit to automatically determine and adjust the target torque value based on detected impact characteristics and rotation angles. The system performs self-calibration and automatic parameter adjustment without requiring external intervention or manual parameter setting, thereby maintaining manufacturing precision while eliminating time loss associated with parameter adjustment
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
Enables easy setting of parameter values for torque management, reducing the time and labor required to achieve target torque values by allowing for real-time adjustment and storage of optimal parameter settings during tightening operations.
Implementation Method 1
an impact detection unit that detects an impact applied by the impact mechanism to the output shaft
Data Source
AI summary
A mode setting unit sets a parameter setting mode or a work mode. A parameter setting unit sets a plurality of parameter values in the parameter setting mode. A torque estimation unit calculates a tightening torque value by using a detection result from an impact detection unit. In a work mode, a control unit stops a rotation of a motor based on the plurality of parameter values set by the parameter setting unit and in accordance with the tightening torque value calculated by the torque estimation unit. In the parameter setting mode, a work information storage unit stores the tightening torque value calculated by the torque estimation unit during a tightening work according to a user operation, and the parameter setting unit sets the plurality of parameter values based on the tightening torque value stored in the work information storage unit.