Modular Torque Multiplier with Expandable Sleeve
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Solution Overview
Problem
Conventional torque multipliers face inefficiencies in high-torque bolting processes due to heavy weight and high costs associated with multiple stages of reduction gearing mechanisms, which reduce rotation speed and increase worker burden, while attempting to achieve varying torque capacities.
Innovation Solution
A torque capacity expandable device comprising a connection sleeve integrated with a force-applying end fastening mechanism of a torque wrench and a force-applied end fastening mechanism of a customized torque multiplier, forming an integral rigid structure to enhance torque capacity, reduce worker workload, and lower tool costs by allowing flexible connection of low-torque, high-rotation-speed wrenches with customized torque multipliers of different magnification ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple stages of reduction gearing mechanisms are used to achieve high torque capacity, then torque magnification ratio is improved, but device weight increases and rotation speed decreases
Solution Approach 1:
The torque multiplication system is divided into modular components: a first torque multiplier with a first reduction gearing mechanism and a second torque multiplier with a second reduction gearing mechanism. These modular segments can be connected in series to achieve cumulative torque multiplication, allowing the system to attain high torque capacity without requiring a single heavy multi-stage reduction mechanism. Each segment operates independently with its own gear train, reducing the weight penalty associated with monolithic high-ratio reduction mechanisms.
2Force
If multiple stages of reduction gearing mechanisms are used to achieve high torque capacity, then torque magnification ratio is improved, but rotation speed decreases
Solution Approach 1:
The overall reduction ratio is achieved through multiple independent torque multiplier segments connected in series. The first torque multiplier provides a first torque multiplication ratio, and the second torque multiplier provides a second torque multiplication ratio. This segmentation allows the system to achieve high cumulative torque multiplication while maintaining better speed characteristics compared to a single-stage high-ratio mechanism, as each segment contributes a portion of the total reduction ratio.
3Adaptability or versatility
If different torque multipliers are used for different bolting stages, then torque capacity adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The system employs universal connection interfaces that allow the first and second torque multipliers to be connected in various configurations. The same basic torque multiplier design can serve multiple functions by being combined in different arrangements, eliminating the need for entirely different tools for different bolting stages. This modular universality reduces device complexity and inventory requirements while maintaining adaptability across various torque applications.
4Force
If high reduction ratio mechanisms are used, then torque magnification is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The high torque magnification is achieved through multiple simpler reduction gearing mechanisms connected in series rather than a single complex high-ratio mechanism. Each segment contains its own complete but simpler gear train, making individual manufacturing easier and more cost-effective. The modular architecture allows for standardized production of individual torque multiplier units that can then be assembled to achieve the required overall torque multiplication ratio.
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
The solution effectively increases working efficiency, reduces worker burden, and decreases tool costs by enabling resilient expansion of torque capacity with a cost-efficient and easily operable system, capable of achieving various torque stages with reduced weight and complexity.
Implementation Method 1
A torque multiplier is a torque magnification device made by means of a reduction gearing mechanism
Implementation Method 2
Its torque magnification ratios increase with its reduction ratios
Data Source
AI summary
A torque capacity expandable device and method for a torque multiplier are introduced. The device includes a connection sleeve and a torque multiplier. The connection sleeve, fitted to a torque wrench and the torque multiplier and fastened, has a force-applied end corresponding in dimensions to a force-applying end of the torque wrench and has another end corresponding in dimensions to the force-applied end of the torque multiplier. An integral fastening mechanism is integrally fitted to or formed with each of the two ends of the torque multiplier. Its force-applied end fastening mechanism has the same dimensions as the force-applying end fastening mechanism of connection sleeve. Its force-applying end fastening mechanism has the same dimensions as the force-applied end fastening mechanism of a reaction arm disposed at the force-applying end fastening mechanism of torque multiplier.