Optical Qualifier for Clamping Tool Stroke Verification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing clamp tools often fail to verify if a small object impedes a full stroke during clamping, as they rely solely on pressure monitoring, which is insufficient for determining complete stroke completion.
Innovation Solution
The integration of an optical laser sensor with a microprocessor-based system that measures air pressure and distance, allowing for precise verification of the clamping tool's stroke completion by combining pressure thresholds with optical distance verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure monitoring is used to verify clamping completion, then the system is simple to operate, but it cannot detect if a small object impedes full stroke
Solution Approach 1:
The patent combines pressure monitoring and optical laser distance measurement into a single integrated clamping verification system. The microprocessor receives signals from both the pressure transducer and the laser emitter/detector assembly, merging two monitoring approaches to achieve reliable stroke verification while maintaining operational simplicity through unified control logic.
Solution Approach 2:
The monitoring system performs multiple functions: it monitors pressure, measures distance via laser, determines stroke completion, and detects obstructions. This multi-functional approach allows a single system to provide comprehensive verification of clamping operations, improving reliability without requiring separate dedicated devices for each monitoring task.
2Measurement precision
If optical laser sensor is added to verify full stroke, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a laser emitter to project a beam and a separate detector to receive it, with the beam serving as an intermediary carrier of distance information. This intermediary approach enables precise non-contact measurement of stroke distance without requiring direct mechanical contact or complex displacement sensors, thereby improving measurement precision while keeping the added complexity manageable.
3Reliability
If pressure transducer alone is used, then the system is easy to manufacture, but it fails to detect incomplete stroke caused by obstructions
Solution Approach 1:
The patent replaces or supplements mechanical stroke verification with an optical laser measurement system. Instead of relying solely on mechanical pressure indicators, the laser emitter and detector provide an optical field-based measurement method that can detect whether the clamping tool achieves full stroke, thereby improving obstruction detection capability while the modular design keeps manufacturing complexity reasonable.
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 ensures reliable and accurate verification of clamping operations by detecting if the tool reaches a full stroke, enhancing accountability and reliability in clamp tool usage.
Implementation Method 1
The laser emitter is a means for measuring a variable distance of measurement
Data Source
AI summary
This clamping tool uses optical distance verification with a laser. Clamping tools, like all tools, are known to be operated improperly. Many tools verify process completion by monitoring the pressure within the pneumatic tool. Previous qualifiers use pressure to determine many things. However, it often misses if a small object impedes a full stroke. With the addition of an optical laser sensor, we are able to determine if a clamping tool reaches full stroke.