Electromechanical Joining Wear Detection Using Force-Torque Correlation
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Solution Overview
Problem
Existing electromechanical joining systems face challenges in early detection of wear in components, leading to potential system failure and increased maintenance costs.
Innovation Solution
A method that uses sensors to measure force and torque curves during the joining process, with an algorithm linking actual drive values to these additional measurements to detect impending wear, allowing for timely replacement of wear-prone components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wear detection is performed using existing methods with separate monitoring devices and algorithms, then wear can be detected at an early stage, but the device complexity and measurement requirements increase significantly
Solution Approach 1:
The patent combines the monitoring function with the existing force sensor already present in the electromechanical joining system. The force sensor, which is already used to measure temporal force courses during joining processes, is now also utilized to detect wear by analyzing the relationship between force values and drive actuator values. This merging eliminates the need for separate monitoring devices and reduces system complexity while maintaining early wear detection capability.
Solution Approach 2:
The force sensor is given a dual function: it continues to measure force during joining processes and simultaneously serves as a wear detection sensor. By analyzing the correlation between force measurements and drive actuator values, the same sensor provides both process control information and condition monitoring information, reducing the need for additional specialized sensors.
2Measurement precision
If multiple separate sensors are added to measure force and torque for wear detection, then measurement precision improves, but the device complexity and cost increase
Solution Approach 1:
The patent merges the wear detection measurement function with the existing force sensor. Instead of adding separate force and torque sensors, the system uses the force sensor in combination with drive actuator value measurements to detect wear through algorithmic analysis of their relationship, thereby achieving precise wear detection without increasing sensor quantity.
Solution Approach 2:
The control device acts as an intermediary that processes and correlates data from the existing force sensor with drive actuator values. By using the control device's processing capabilities to analyze the relationship between these two data streams, the system achieves precise wear detection without requiring additional physical sensors.
3Reliability
If comprehensive monitoring with multiple sensors is implemented, then reliability of wear detection improves, but the ease of operation and maintenance increase
Solution Approach 1:
The patent combines wear detection functionality with the existing force measurement system, eliminating the need for separate monitoring hardware. This reduces the number of components that require maintenance and calibration, thereby improving ease of operation while maintaining reliable wear detection through the algorithmic analysis of force and drive actuator value relationships.
Data Source
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AI summary
The invention relates to a method for analysing the status of an electromechanical joining system (100), as well as an electromechanical joining system (100) designed for carrying out the method, wherein an output force or an output torque for a joining process carried out by the electromechanical joining system (100) is generated by an electrical drive (10) by means of a screw drive (20), wherein a monitoring unit (14) is supplied with actual values (IW, IW') of the electrical drive (10) as input variables, wherein additional measurement values (ZMW) are determined by a sensor (24) which serves to measure the force or torque curves during the joining process, and the additional measurement values (ZMW) are supplied to the monitoring unit (14) as input variables, and wherein the monitoring unit (14) detects an upcoming wearing of a wear-prone component (21) of the electromechanical joining system (100) from a linking of the supplied actual values (IW, IW') with the supplied additional measurement values (ZMW).