Pulse Torque Driver for Low Reaction Force Fastening
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Solution Overview
Problem
Conventional torque tools cause discomfort to users due to continuous and large reaction forces experienced by the hand, necessitating the use of reaction bars or immovable jigs, which can be cumbersome and costly.
Innovation Solution
A torque tool with a reaction force mitigation system that applies torque in discrete pulses, limiting torque to a predetermined threshold and alternating with periods of zero torque application, using a controller to manage motor operation based on detected torque levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous torque is applied to the fastening element, then the fastening element is tightened effectively, but the user experiences large continuous reaction forces causing discomfort
Solution Approach 1:
The torque tool applies torque to the fastening element in periodic pulses rather than continuous application. The controller alternates between applying torque and pausing, creating a pulsed operation mode that reduces the continuous reaction force on the user's hand while maintaining effective fastening through cumulative torque application over multiple pulses.
2Reliability
If high torque is applied to ensure proper fastening, then fastening reliability is improved, but the reaction force on the user's hand increases causing discomfort
Solution Approach 1:
The total torque required for proper fastening is segmented into multiple smaller torque pulses rather than applying one large continuous torque. The controller manages multiple torque application cycles, each delivering a portion of the total required torque, which reduces the peak reaction force experienced by the user in any single moment while achieving the cumulative torque needed for reliable fastening.
3Ease of operation
If torque is applied in pulses with zero torque intervals, then user comfort is improved by reducing continuous reaction forces, but the fastening process takes longer
Solution Approach 1:
The controller implements periodic torque pulses with optimized timing and duration to balance user comfort with fastening efficiency. By carefully controlling the pulse width, frequency, and total number of pulses, the system maintains acceptable fastening speed while providing relief intervals that reduce continuous reaction force exposure to the user.
Data Source
AI summary
An aspect of the present disclosure is drawn to a system for use with a torque tool and a fastening element. The torque tool has a motor and an engaging mechanism. The engaging mechanism can transfer a first torque to the fastening element when the motor operates in a first rotation mode and can transfer a second torque to the fastening element when the motor operates in a second rotation mode. The system includes a torque detector that detects a magnitude of torque applied to the fastening element and outputs a torque signal; and a controller that outputs a first drive signal to cause the motor to operate in the first rotation mode and outputs a second drive signal to cause the motor to operate in the second rotation mode based on the torque signal.