Inclinometer-Based Tool Orientation for Fastener Assembly Control
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Solution Overview
Problem
Existing fastening tools, such as nutrunners, require multiple programs for different types of fasteners, leading to potential faults in the production process due to incorrect program selection, and often necessitate switching between tools, which adds burden and risk of errors.
Innovation Solution
Incorporating an inclinometer in the tool to determine its inclination and transmit an indicator to a controller, allowing the controller to select the appropriate tightening program based on the tool's position, ensuring optimal fastening for various types of fasteners without the need for manual program switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple programs are added to a controller for different fastener types, then the tool can tighten various fasteners, but the complexity of program selection increases and introduces potential faults
Solution Approach 1:
The inclinometer automatically detects the tool's orientation and triggers the appropriate program without user intervention. The system serves itself by autonomously selecting the correct program based on physical orientation, eliminating manual program selection and reducing complexity.
Solution Approach 2:
The system changes the control parameter from manual program selection to automatic inclination-based selection. By using the physical parameter of tool orientation (inclination angle) as the trigger, the system automatically adapts the tightening program to match the fastener type, resolving the contradiction between versatility and complexity.
2Ease of operation
If a compromise program is used for multiple fastener types, then tool switching is eliminated, but the tightening quality is not optimal for either fastener type
Solution Approach 1:
The system dynamically selects the appropriate tightening program based on the real-time inclination of the tool. Instead of using a static compromise program, the system adapts its parameters (torque, speed, angle) according to the detected orientation, ensuring optimal tightening quality for each fastener type while maintaining operational continuity.
Solution Approach 2:
The tightening parameters are changed dynamically based on inclination detection. The system adjusts torque values, rotational speed, and tightening angles according to the detected fastener orientation, allowing optimal performance for different fastener types without requiring manual program switching.
3Adaptability or versatility
If manual program switching is required between fastener types, then versatility is achieved, but the risk of selecting the wrong program increases
Solution Approach 1:
The inclinometer provides continuous feedback about the tool's orientation to the controller. This feedback mechanism ensures that the correct program is automatically selected based on the physical state of the tool, eliminating human error in program selection while maintaining versatility across different fastener types.
Solution Approach 2:
The manual mechanical selection process (user choosing programs) is replaced with an automated sensing system (inclinometer). The mechanical/physical parameter of tool orientation is converted into an electronic signal that automatically triggers the appropriate program, replacing human decision-making with a reliable sensor-based system.
4Manufacturing precision
If tools are switched between different fastener types, then optimal tightening for each fastener is achieved, but production burden and time increase
Solution Approach 1:
A single tool is made multi-functional through the inclinometer-based program selection system. The tool can handle multiple fastener types with optimal tightening parameters by automatically detecting orientation and selecting appropriate programs, eliminating the need for multiple specialized tools while maintaining productivity.
Solution Approach 2:
The system performs preliminary detection of tool orientation before the tightening operation begins. By detecting the inclination in advance and pre-selecting the appropriate program, the system ensures optimal tightening parameters are ready before operation, maintaining precision without adding time to the production process.
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
This solution enables precise and efficient tightening of different fasteners by automatically selecting the correct program based on the tool's inclination, reducing errors and production process burdens by eliminating the need for manual program selection and tool switching.
Implementation Method 1
an inclinometer configured to determine a first inclination of the tool
Data Source
AI summary
In an embodiment herein, a tool is described. The tool comprises an inclinometer configured to determine a first inclination of the tool; and transmit a first indicator to a controller in response to determining the first inclination of the tool. The tool further comprises a controller interface configured to receive a first program from the controller in response to transmitting the first indicator. The tool further comprises a tool head configured to tighten a first fastener based, at least in part, on the first program.