Screw Connection Assembly for Accurate Pretensioning Force
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Solution Overview
Problem
The calculation of pretensioning force for screw connections is challenging due to its dependence on various influence factors, leading to inaccurate measurements and inefficient quality assurance, especially in automated manufacturing environments, where the relationship between design and process control parameters is complex and influenced by multiple factors.
Innovation Solution
A method and system that determine the required pretensioning force based on operating loads, using a simple computing model to establish nominal expressions for assembly parameters like tightening torque and angle, and then adjust these parameters based on recorded influence factors, such as friction ratios and surface roughness, to achieve accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If auxiliary variables (tightening torque and tightening angle) are used to control the assembly process, then the assembly process can be monitored and controlled, but the measurement precision of the actual pretensioning force is insufficient due to multiple influence factors
Solution Approach 1:
The patent introduces a calculation unit that acts as an intermediary between the auxiliary variables (tightening torque, tightening angle) and the design parameter (pretensioning force). This calculation unit uses a computing model to determine the actual pretensioning force based on recorded influence factors, thereby improving measurement precision without directly measuring the pretensioning force itself.
Solution Approach 2:
The patent replaces direct mechanical measurement of pretensioning force with a computational approach. Instead of using complex mechanical sensors to measure pretensioning force directly, the system uses a computing model that processes auxiliary variables and influence factors to calculate the pretensioning force, thereby reducing device complexity while improving measurement accuracy.
2Manufacturing precision
If multiple influence factors are considered to improve assembly accuracy, then the pretensioning force determination becomes more accurate, but the assembly process becomes more time-consuming and personnel-intensive
Solution Approach 1:
The patent records multiple influence factors (friction ratios, surface roughness, thread geometry) before and during the assembly process in advance. By having this data prepared beforehand, the calculation unit can quickly determine the pretensioning force without requiring time-consuming measurements or manual calculations during assembly, thereby improving both accuracy and efficiency.
Solution Approach 2:
The system enables self-service by automatically recording influence factors and calculating the pretensioning force without requiring personnel intervention. The recording unit automatically captures data, and the calculation unit autonomously determines the assembly parameters, eliminating the need for skilled operators to manually assess multiple influence factors during assembly.
3Reliability
If further tightening torque measurements are performed to verify pretensioning force, then quality assurance is improved, but the process becomes more time-consuming and requires experienced personnel
Solution Approach 1:
The patent implements a feedback mechanism where the calculation unit continuously determines the pretensioning force based on recorded influence factors and auxiliary variables. This real-time feedback allows for immediate quality assurance without requiring separate verification measurements, as the system continuously monitors and adjusts the assembly process based on calculated pretensioning force values.
Solution Approach 2:
The patent creates a virtual model of the assembly process through the computing model that calculates pretensioning force based on auxiliary variables and influence factors. This virtual copy allows for quality assurance through calculation rather than physical measurement, eliminating the need for time-consuming additional torque measurements while maintaining reliability.
Data Source
AI summary
A method and a system for assembling a screw connection for a predefined operating load. The system includes a detector configured to detect values of at least one influence factor on the screw connection, a calculator configured to determine, based on the operating load, a required pretensioning force of the screw connection, and, based on the determined pretensioning force, to determine an expression of at least one assembly parameter, and an assembler configured to assemble the screw connection in accordance with the determined expression of the assembly parameter.