Sensor-Guided Screw Assembly Verification for Torque and Placement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for ensuring correct assembly of screwed components, such as screws and nuts, are time-consuming, prone to human error, and lack assurance of proper placement and selection, especially in critical applications like aeronautical and military equipment.
Innovation Solution
A device comprising a screw gun with torque and angle sensors, connected to computer equipment, that measures and compares assembly parameters against reference data to ensure correct placement, selection, and order of screws, using presence detectors to verify compliance with predefined standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual endorsement with color marks is used, then operator involvement is achieved, but time consumption and human error increase
Solution Approach 1:
The patent replaces the manual mechanical endorsement system (color mark application) with an automated sensor-based measurement system. Torque sensors and angle sensors automatically measure assembly parameters, eliminating the need for manual color marking while providing more reliable and immediate verification of assembly correctness.
Solution Approach 2:
The assembly system performs self-verification through integrated sensors that automatically monitor torque and angle during the assembly process. The system provides real-time feedback and automatic endorsement without requiring separate manual intervention for verification, thus reducing both time and potential human error.
2Reliability
If operator endorsement is performed, then moral involvement is achieved, but actual guarantee of correct assembly is not provided
Solution Approach 1:
The patent implements a feedback system where sensors continuously monitor torque and angle parameters during assembly, comparing them against predefined specifications. This provides objective, real-time verification of assembly correctness, replacing subjective operator judgment with measurable, verifiable data that guarantees proper assembly execution.
Solution Approach 2:
The patent introduces measurement sensors and computer equipment as intermediaries between the operator and the assembly verification process. These intermediaries objectively measure and record assembly parameters, providing an impartial verification mechanism that ensures correct assembly regardless of operator involvement or intent.
3Reliability
If dismounting is required to verify assembly, then complete verification is achieved, but productivity is reduced
Solution Approach 1:
The patent performs verification measurements during the assembly process itself, rather than requiring post-assembly dismounting for inspection. Torque and angle sensors continuously monitor parameters throughout assembly, providing complete verification before the assembly is finalized, thus eliminating the need for time-consuming dismounting operations.
Solution Approach 2:
The patent maintains continuous measurement and verification throughout the entire assembly process, rather than interrupting production for separate verification steps. The sensors operate continuously during assembly, providing ongoing verification that maintains productivity while ensuring complete assembly correctness.
4Reliability
If color marks are applied to all assemblies, then complete endorsement is achieved, but applicability is limited by surface constraints
Solution Approach 1:
The patent replaces the surface-dependent color mark system with a measurement-based verification system that does not require physical marks on the assembly surfaces. Sensors measure torque and angle parameters directly, providing endorsement information through digital signals rather than visual marks, thus overcoming surface compatibility limitations.
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
Ensures accurate and efficient assembly by providing real-time notifications of non-conformities, reducing human error and ensuring that screws are correctly placed and selected, thereby enhancing the reliability of mechanical assemblies.
Implementation Method 1
the screw gun being equipped with measurement sensors sending information representative of the torque applied by the screw gun
Implementation Method 2
the screw gun being equipped with measurement sensors sending information representative of the torque applied by the screw gun and an angle of rotation applied by the screw gun
Data Source
AI summary
A device for endorsing screwed assemblies, includes a screw gun intended to be handled by an operator, and computer equipment connected to the screw gun, the screw gun being equipped with measurement sensors sending information representative of the torque applied by the screw gun and an angle of rotation applied by the screw gun, the computer equipment storing, in a memory, reference data relating to a screwed assembly to be produced, the computer equipment being configured to compare information representative of the angle and the torque measured during the assembly with the reference data, and to provide a notification as to the conformity of the measurements of the angle and the torque in relation to the reference data.