Pneumatic Impact Wrench Torque Control via Magnetic Sensing
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Solution Overview
Problem
Existing impact tools lack precise control over torque application during wheel tightening, risking damage to bolts and hubs, especially under high dynamic stress conditions like car racing, where reliable and timely tightening is crucial.
Innovation Solution
Integration of a contactless torque sensor system with a control unit that uses magnetic field sensors and coils to monitor and control the torque applied by the output shaft, allowing for precise detection of the desired torque threshold and automatic tool shutdown when reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the impact tool rotates the screwdriver fast to ensure rapid wheel tightening, then productivity is improved, but the risk of damaging the bolt and hub increases due to excessive torque
Solution Approach 1:
The patent employs a torque sensor that continuously monitors the torque applied to the screwdriver in real-time and feeds this information back to a control unit. When the torque reaches a predetermined threshold that could cause damage, the control unit automatically stops the tool, thus preventing bolt and hub damage while allowing high-speed operation.
Solution Approach 2:
The patent replaces traditional mechanical torque limiting mechanisms with an electronic control system comprising torque sensors, control units, and automated shutdown functionality. This substitution enables precise torque monitoring and control without mechanical complexity, allowing fast operation with digital precision in torque management.
2Reliability
If the impact tool applies high torque to ensure reliable coupling under high stress conditions, then reliability is improved, but the risk of damaging the screw coupling increases
Solution Approach 1:
The torque sensor provides continuous feedback on the actual torque applied to the screw coupling, allowing the control unit to maintain torque within safe boundaries that ensure reliable coupling without exceeding damage thresholds, even under high dynamic stress conditions.
Solution Approach 2:
The system dynamically adjusts the operational parameters by monitoring torque in real-time and automatically stopping when a predetermined torque threshold is reached. This parameter control ensures the coupling achieves necessary tightness for reliability while preventing over-torquing that would cause damage.
3Measurement precision
If contactless torque sensors are integrated into the impact tool for precise torque monitoring, then measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent uses contactless torque sensors that employ magnetic field detection instead of mechanical contact sensors. This substitution eliminates mechanical wear and complex mechanical linkages while providing precise torque measurement through electromagnetic fields, reducing mechanical complexity while maintaining high measurement accuracy.
Solution Approach 2:
The contactless torque sensor acts as an intermediary that measures torque through magnetic field interactions without direct mechanical contact. This intermediary approach enables precise torque monitoring while avoiding the complexity and wear associated with mechanical contact sensors, as the measurement is performed through field interactions.
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
Ensures reliable and precise tightening of wheel bolts, preventing damage and maintaining coupling integrity under high stress conditions, while being lightweight and robust enough for critical applications.
Implementation Method 1
measuring the torque on the output shaft of a pneumatic impact tool, using contactless sensors of magnetic type
Implementation Method 2
a rotating mass (hammer), that acts as a flywheel for storing mechanical energy
Implementation Method 3
can be driven, for example, by a cam system
Data Source
AI summary
In a pneumatic impact wrench there is an output shaft that is connectable in a removable manner to a screw coupling member; a torque sensor, which is mounted on the shaft, sends signals to a control unit that calculates the energy transferred through the output shaft and controls the wrench on the basis of a comparison between the calculated energy and a predefined threshold value.