Electric Screwdriver Adaptive Torque Control for Precision Fastening
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Solution Overview
Problem
Conventional electric screwdrivers lack precision in controlling fastening strength and rotational speed, leading to inconsistent and potentially damaging screw fastening, especially in applications requiring uniformity, such as circular valves, due to fixed torque and human error factors.
Innovation Solution
An electric screwdriver apparatus with a controller that includes a motor module, sensing module, and processing module to precisely control rotational speed and torque, allowing for customizable fastening profiles, including hard and soft stops, to ensure uniform screw fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electric screwdriver with fixed torque is used, then device complexity is low, but manufacturing precision of screw fastening deteriorates
Solution Approach 1:
The patent implements dynamic control of rotational speed and torque during the screw fastening process. The controller adjusts rotational speed in multiple stages (acceleration phase, constant speed phase, deceleration phase) and dynamically adjusts torque based on real-time feedback from the sensing module, transforming the fixed-torque system into a dynamic adaptive system that maintains precision while managing complexity through structured control phases.
Solution Approach 2:
The patent incorporates a sensing module that provides real-time feedback on torque, rotational speed, and rotation time during the fastening process. The controller uses this feedback to adjust operational parameters dynamically, creating a closed-loop control system that ensures precise screw fastening while managing system complexity through intelligent feedback-based adjustment.
2Reliability
If user manually controls rotational speed by pressing strength, then device complexity is low, but reliability of fastening process deteriorates
Solution Approach 1:
The patent enables the system to self-regulate the fastening process through automated control. The controller automatically manages acceleration, constant speed, and deceleration phases based on pre-set parameters and real-time feedback, eliminating the need for manual pressing strength adjustment by the user. This self-service approach ensures consistent reliability while the added complexity is managed through automated algorithms.
3Manufacturing precision
If conventional electric screwdriver operates at high rotational speed, then productivity is high, but manufacturing precision of screw fastening deteriorates
Solution Approach 1:
The patent implements periodic action by dividing the fastening process into distinct phases: acceleration phase, constant speed phase, and deceleration phase. Each phase serves a specific purpose and operates at optimized speeds. This periodic structure allows the system to maintain high productivity during the constant speed phase while ensuring precision during acceleration and deceleration phases, resolving the contradiction between speed and precision.
Solution Approach 2:
The patent uses dynamic speed adjustment to optimize both productivity and precision. The controller adjusts rotational speed based on the fastening phase and real-time feedback, allowing high speeds during stable fastening while reducing speeds during critical phases like initial engagement and final tightening. This dynamic approach maintains productivity while ensuring precision requirements are met.
Data Source
AI summary
The electric screwdriver apparatus control method is executed by an electric screwdriver apparatus. A processing module of the electric screwdriver apparatus loads a configuration data, and the processing module controls a motor module to accelerate a rotational speed to a target rotational speed. When a revolution number exceeds a first revolution number, the processing module controls the motor module to decelerate to a first rotational speed. When a torque value exceeds a first torque value, the processing module determines whether a fastening process of a screw ends with a hard stop or a soft stop according to the configuration data. If the fastening process ends with the hard stop, then the screw is additionally tightened for a hard stop angle, vice versa. The processing module tightens the screw according to the configuration data, the torque value and a rotational speed value, improving the process of fastening the screw.