Nut Runner Position Tracking for Automatic Torque Selection
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Solution Overview
Problem
Existing nut runner systems face limitations in handling freedom and position detection, leading to restricted operation areas and potential erroneous torque selection, with conventional methods either restricting movement or requiring costly and large equipment for precise positioning.
Innovation Solution
A control system utilizing a marker on the nut runner, imaged by a camera to detect its three-dimensional position, and a controller to set a target tightening torque value based on this position, enabling precise torque control and detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a nut runner is supported by an arm to enable operation on tightened members with large tightening reaction force, then the tightening capability is improved, but the movement range and orientation freedom of the nut runner are restricted
Solution Approach 1:
The system separates the nut runner into two operational modes: arm-supported mode for high-torque applications and hand-held mode for flexible positioning. This segmentation allows each mode to optimize for its specific function without compromise.
Solution Approach 2:
The system dynamically adapts the support mechanism based on operational needs. The arm provides support when high tightening force is required, while allowing hand-held operation when flexibility and movement freedom are prioritized, creating a dynamic rather than static support system.
2Adaptability or versatility
If a hand nut runner is used to achieve free handling and movement, then the degree of freedom is improved, but the position of the nut runner cannot be detected
Solution Approach 1:
A marker is introduced as an intermediary element attached to the nut runner. This marker serves as a mediator between the hand-held nut runner and the detection system, enabling position detection without interfering with the operator's free handling of the tool.
Solution Approach 2:
The system replaces complex mechanical position detection mechanisms with an optical detection system using a camera and marker. This substitution maintains handling freedom while enabling accurate position measurement through non-contact optical methods.
3Manufacturing precision
If multiple nut runners are prepared for different tightening torques to enable precise torque selection, then the tightening precision is improved, but the complexity of selection and management increases and errors may occur
Solution Approach 1:
The system makes a single nut runner universal by enabling dynamic torque configuration based on position. Instead of requiring multiple specialized nut runners for different torques, one nut runner can adapt to different torque requirements automatically determined by its detected position and the corresponding workpiece location.
Solution Approach 2:
The system uses feedback from position detection (via marker and camera) to automatically determine the appropriate tightening torque. The detected position feeds into the control system, which retrieves the correct torque value from stored data, eliminating manual selection and reducing errors.
4Measurement precision
If a three-dimensional measuring device is used to detect the position of the nut runner, then the position detection accuracy is improved, but the equipment size and cost increase
Solution Approach 1:
The system uses a relatively simple and inexpensive camera combined with a marker instead of complex and expensive three-dimensional measuring devices. This approach achieves sufficient position detection accuracy for the application while significantly reducing equipment cost and complexity.
Solution Approach 2:
The system creates a visual copy (image) of the marker on the nut runner using a camera, then processes this image to determine position. This copying approach simplifies the measurement system compared to direct three-dimensional sensing, achieving acceptable accuracy at lower cost.
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
Enables easy and precise setting of target tightening torque values, reducing errors and enhancing traceability of tightening operations.
Implementation Method 1
a camera that remotely images the marker and detects a position of the tightener
Data Source
AI summary
A control system 100 for a tightener (nut runner 10) of the present invention includes a marker M provided on the tightener, a camera 31 (32) that remotely images the marker M and detects a position of the tightener, and a controller that stores a target tightening torque value of a plurality of tightened members (bolts B) together with position information of the tightened members, and sets a tightening torque value of the tightener for each of the tightened members to be tightened by the tightener on the basis of the position of the tightener detected by the camera.