Replaceable Torque Sensor Connection Element for Electronic Wrench
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Solution Overview
Problem
Existing electronic torque wrenches require multiple models for different measurement ranges and are costly to maintain, as they need to be calibrated in specialized labs, and repairs are complex, leading to inefficiencies in use and maintenance.
Innovation Solution
An electronic torque wrench design with a removable and replaceable connection element containing torque sensors and calibration data, allowing for quick adaptation to various measurement ranges and easy sensor replacement without the need for recalibration, using a quick coupling mechanism for mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple torque wrench models are used to cover different measurement ranges, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The wrench body is designed as a universal platform that can accommodate multiple connection elements with different torque sensors. The standardized interface and calibration system allow a single wrench body to perform multiple measurement functions across different torque ranges, eliminating the need for multiple dedicated wrench models.
Solution Approach 2:
The torque measurement system is segmented into two independent parts: a reusable wrench body and replaceable connection elements. Each connection element contains a torque sensor calibrated for a specific measurement range. This segmentation allows users to swap connection elements rather than replacing entire wrenches, reducing complexity while maintaining precision across ranges.
2Measurement precision
If torque sensors are integrated into an indissoluble unit, then measurement precision is maintained, but ease of repair and adaptability deteriorate
Solution Approach 1:
The torque sensor is segmented from the wrench body and placed in a separate, replaceable connection element. This allows the sensor to be easily removed and replaced without affecting the wrench body or requiring complex calibration procedures, significantly improving ease of repair while maintaining measurement precision through pre-calibrated replacement elements.
Solution Approach 2:
The connection element containing the torque sensor is designed as a consumable or easily replaceable component. Rather than repairing complex integrated sensors, users can replace the entire connection element with a pre-calibrated unit, simplifying maintenance and reducing downtime while ensuring measurement accuracy.
3Measurement precision
If torque sensors are integrated into an indissoluble unit, then measurement precision is maintained, but adaptability to different measurement ranges deteriorates
Solution Approach 1:
The wrench body incorporates a universal connection interface that accepts multiple types of connection elements, each with different torque sensors calibrated for specific measurement ranges. This allows a single wrench body to adapt to various measurement requirements by simply changing the connection element, greatly enhancing versatility while maintaining precision.
Solution Approach 2:
The system transitions from a static, fixed-configuration wrench to a dynamic, reconfigurable system. Users can dynamically adjust the measurement range by swapping connection elements based on the specific task requirements, allowing the wrench to adapt to different measurement scenarios while maintaining accurate measurements through pre-calibrated sensors.
4Measurement precision
If calibration is performed in specialized laboratories, then measurement precision is ensured, but loss of time increases
Solution Approach 1:
Calibration is performed in advance during the manufacturing process. Each connection element is pre-calibrated at the factory for its specific measurement range and comes with stored calibration data. This preliminary calibration eliminates the need for time-consuming on-site laboratory calibration, allowing users to immediately use the connection elements upon receipt or replacement while ensuring measurement precision.
Solution Approach 2:
The calibration data is copied and stored in memory within each connection element during manufacturing. Rather than performing physical calibration procedures in the field, the pre-copied calibration data enables the sensor to operate accurately immediately upon installation, dramatically reducing calibration time while maintaining measurement precision.
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 fast adaptability to a broad range of torque measurements, reduces tool downtime, and simplifies maintenance by allowing users to easily switch between pre-calibrated connection elements, eliminating the need for complex recalibration and specialized equipment.
Implementation Method 1
such types of wrench are made like a bending-bar transducer having extensometers for measuring the deformation proportionate to the transmitted torque
Data Source
Figure 1~2
AI summary
An electronic torque wrench (10) comprising a grip body (11) with a user interface (12) and a control electronics (13) for controlling the wrench. From one extremity of the grip body protrudes a mechanical connection element (14) that terminates at one extremity with a tightening head (16). In the connection element are torque sensors (18) for determining the torque transmitted between the grip body and the head and the connection element (14) is connected in a removable and replaceable way to the grip body (11) and comprises memory means (19) containing data for calibrating the wrench to such connection element (14) and means for transferring such data to the control electronics.