Screw Connection Tightening With Angle-Based Bolt Force Documentation
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Solution Overview
Problem
Existing screw tensioning devices lack systematic documentation of operating parameters and data for screw connections, leading to inconsistent tightening forces and torque values, which can compromise safety and quality in critical applications like reactor or storage containers.
Innovation Solution
A method involving a rotary drive and axial tensioning device that calculates and documents the longitudinal force in the threaded bolt by measuring rotation angles and thread geometry, storing this data with a unique identifier in a documentation module, ensuring precise and reproducible tightening processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw tensioning devices are used without systematic detection and documentation of operating parameters, then the device complexity is reduced and ease of operation is improved, but the reliability and manufacturing precision of the screw connection are worsened
Solution Approach 1:
The tensioning device is designed to perform multiple functions: axial tensioning of the bolt, rotation of the nut via the rotary drive, detection of rotation angle through the sensor, and documentation of all operating parameters including longitudinal force calculation. This multi-functionality integrates what would otherwise be separate systems into a unified device, improving reliability without proportionally increasing complexity.
Solution Approach 2:
A sensor detects the rotation angle of the rotary drive during nut tightening, and this information is fed back to a process control unit. The control unit calculates the longitudinal force in the bolt based on the detected rotation angle and thread pitch, and documents this data. This feedback mechanism ensures precise control and documentation of the tightening process, directly improving screw connection reliability.
2Manufacturing precision
If rotation angle detection and longitudinal force calculation are implemented, then the manufacturing precision of the tightening process is improved, but the device complexity increases due to additional sensors and computing apparatus
Solution Approach 1:
The system replaces direct mechanical measurement of bolt tension with an indirect method: a sensor detects the rotation angle of the rotary drive, and a process control unit calculates the longitudinal force based on this rotation angle and the known thread pitch of the bolt. This substitution of mechanical measurement with sensor-based detection and computational calculation improves precision while managing device complexity through software-based solutions.
3Loss of information
If comprehensive documentation of operating parameters is implemented, then the loss of information is reduced, but the device complexity and loss of time for data processing increase
Solution Approach 1:
The sensor continuously detects the rotation angle of the rotary drive throughout the tightening process, and the process control unit continuously calculates and documents the longitudinal force and other operating parameters. This continuous detection and documentation ensures no information is lost during the tightening process, capturing all relevant data in real-time without requiring separate measurement steps that would increase time loss.
Data Source
AI summary
In a tightening method for a screw connection of a bolt and a nut by using a tensioning device, a rotary drive, and a process control unit with documentation module, the nut is tightened with the rotary drive by a tightening moment required for the nut to bear against a support. The screw connection is elongated by exerting axial tension on a threaded end of the bolt protruding from the nut. The nut is further tightened while maintaining elongation, and a rotation angle covered during further tightening is detected by a rotation angle sensor. Lengthening of the bolt is calculated from the rotation angle and thread geometry of the screw connection. A longitudinal force in the threaded bolt is calculated from lengthening of the bolt, bolt diameter and bolt length. The calculated longitudinal force and an identifier identifying the screw connection are stored in the documentation module.