Motor Torque Verification Using Multi-Source Feedback Control
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Solution Overview
Problem
Existing power tools, such as electric screwdrivers and wrenches, face challenges in accurate torque control, leading to issues like broken screws or bolts due to inaccurate torque values influenced by environmental factors, equipment aging, and sensor accuracy, which affect the efficiency and reliability of non-professional users.
Innovation Solution
A torque control method and device that utilizes multiple torque values from user input, motor parameters, and torque sensors to verify effectiveness through difference calculations and relationships, ensuring accurate torque control without increasing processing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If torque values are calculated according to motor parameters (current, etc.), then torque control can be implemented, but the torque values may differ from actual torque values due to environmental factors, equipment aging, and wear
Solution Approach 1:
The patent implements a feedback mechanism by comparing the calculated torque value (first torque value) with the actual torque value detected by the torque sensor (second torque value). The control unit calculates the difference between these two values and uses this feedback to adjust future torque calculations, thereby improving accuracy over time while maintaining ease of operation.
Solution Approach 2:
The patent replaces direct reliance on mechanical torque sensing alone with a hybrid approach that combines motor parameter calculation (electrical measurement) with torque sensor detection. This substitution allows the system to cross-validate torque values and compensate for the limitations of each individual method.
2Measurement precision
If torque values are detected by torque sensors, then actual torque values can be obtained, but the detected values may differ from actual torque values due to sensor accuracy, equipment aging, and environment
Solution Approach 1:
The system uses feedback by continuously comparing the torque sensor's detected values with the motor parameter-calculated values. When discrepancies exceed a threshold, the system triggers alerts and adjusts control parameters, ensuring long-term reliability despite sensor drift or environmental changes.
Solution Approach 2:
The control unit acts as an intermediary that reconciles the two different torque measurement approaches. It processes both the calculated torque value and the detected torque value, determines their validity through comparison, and uses the reliable value for control decisions, thereby ensuring consistent and reliable torque control.
3Measurement precision
If complex verification methods are used to verify torque effectiveness, then torque accuracy can be improved, but the power tools may exceed their processing capacity and cause downtime
Solution Approach 1:
The patent applies partial verification by not continuously performing full complexity checks. Instead, it uses threshold-based comparison and only triggers detailed verification processes when necessary (e.g., when difference values exceed predetermined thresholds), thereby maintaining high processing efficiency while ensuring adequate torque verification accuracy.
Solution Approach 2:
The verification process is segmented into multiple levels: a quick threshold comparison (first level) and a more detailed verification (second level) triggered only when needed. This segmentation allows the system to maintain high processing speed for normal operations while performing thorough verification only when anomalies are detected, thus avoiding downtime.
4Measurement precision
If multiple torque values are obtained and verified through difference calculations, then torque accuracy is improved, but the device complexity increases
Solution Approach 1:
The control unit is designed with multi-functionality, serving both as the motor controller and the torque verification system. It performs multiple functions including calculating torque from motor parameters, detecting torque via sensor, comparing values, determining validity, and triggering alerts. This universal design improves torque accuracy without requiring separate dedicated verification hardware, thus limiting the increase in device complexity.
Data Source
AI summary
The application provides a torque control method and device. The application verifies an effectiveness of a torque according to the first torque value Tset of set by user, the second torque value Ti obtained by gathering parameters, and the third torque value Ts uploaded by one or more torque sensors, and controls operating states of a motor according to the effectiveness of the torque. The application determines whether the torque value is normal and effective by comparing torque values obtained in various ways, greatly improves the accuracy of the torque and improves the control effect of the motor. The application has the advantages of simple processing process, low requirement on the processing capacity of the device, and can realize torque verification without increasing the processing capacity of the equipment, thus reducing the cost and improving the user experience.