Electric Pulse Tool Torque Control With Reverse Pulse Correction
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Solution Overview
Problem
Electric pulse tools face challenges in accurately controlling torque during tightening operations, leading to reduced accuracy and increased risk of exceeding target torque, which can result in unsuccessful tightening and potential damage to screw joints.
Innovation Solution
An electric pulse tool equipped with sensors and a processor that delivers torque pulses in two directions, adjusting the torque to reach and maintain a target value within predetermined intervals, allowing for self-correction if the parameter value exceeds the target, thereby reducing the need for manual corrections and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric pulse tool provides powerful torque pulses to tighten screw joints quickly, then productivity is improved, but accuracy deteriorates due to increased risk of missing the target torque
Solution Approach 1:
The patent segments the tightening process into multiple small torque pulses instead of using fewer large torque pulses. This segmentation allows the tool to deliver cumulative torque while maintaining fine control over the final torque value, thereby achieving both high productivity and high accuracy.
Solution Approach 2:
The patent dynamically adjusts the torque pulse characteristics based on real-time feedback from sensors. The control system modifies subsequent torque pulses according to the measured parameter values, enabling adaptive control that maintains accuracy while achieving rapid tightening through optimized pulse sequences.
2Use of energy by moving object
If the electric pulse tool provides fewer torque pulses, then energy efficiency is improved, but accuracy deteriorates due to increased risk of exceeding target torque
Solution Approach 1:
The patent divides the torque application into multiple small pulses rather than fewer large pulses. This segmentation enables more precise control over the cumulative torque, reducing the risk of exceeding the target while maintaining energy efficiency through optimized pulse数量和强度.
Solution Approach 2:
The patent implements a feedback mechanism where sensors monitor the tightening parameter after each torque pulse. The control system uses this feedback information to adjust subsequent pulses, ensuring the target torque is reached accurately without waste, thereby improving both precision and energy efficiency.
3Productivity
If the electric pulse tool delivers high torque pulses to reduce tightening time, then productivity is improved, but reliability deteriorates due to increased risk of unsuccessful tightening
Solution Approach 1:
The patent segments the torque delivery into multiple controlled pulses, which reduces the risk of any single pulse causing unsuccessful tightening. This segmented approach maintains productivity by keeping the total tightening time short while improving reliability through finer control.
Solution Approach 2:
The patent uses real-time feedback from sensors to monitor the tightening process and adjust subsequent torque pulses accordingly. This feedback mechanism ensures that the tightening remains within successful parameters, significantly reducing the risk of unsuccessful tightening while maintaining rapid operation.
4Productivity
If the electric pulse tool provides powerful torque pulses, then productivity is improved, but ease of operation deteriorates due to increased reaction force on the operator
Solution Approach 1:
The patent segments the total torque into multiple smaller pulses, which reduces the peak reaction force experienced by the operator during each pulse. This segmentation maintains productivity through cumulative torque delivery while significantly improving ease of operation by reducing ergonomic strain.
Data Source
AI summary
An electric pulse tool for performing tightening operations, where torque is delivered in pulses to tighten a screw joint, includes an output shaft, a sensor arranged to determine a parameter value associated with the tightening of the screw joint, a processor, and a memory containing instructions executable by the processor. The electrical pulse tool operates to provide torque pulses on the output shaft in a first direction until the determined parameter value associated with the tightening of the screw joint reaches within or above a predetermined first interval including a target parameter value. The electrical pulse tool also operates to provide at least one torque pulse on the output shaft in a second direction that is opposite to the first direction in case the determined parameter value exceeds the target parameter value within a predetermined second interval.