Sensor Wrench for Precision Fluid Connection Tightening
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Solution Overview
Problem
The existing methods for connecting fluid piping fittings often result in inconsistent tightening, leading to either over-tightening or under-tightening, which can cause leaks and stress on the components, especially when dealing with corrosive, pyroforic, and toxic fluids, due to the subjective nature of 'finger tightening' and misalignment of glands and gaskets.
Innovation Solution
A wrench equipped with strain gauges and a gyroscope that monitors the strain during tightening to ensure full contact between glands and gaskets, providing a mechanical standard for accurate tightening by correlating strain with alignment conditions and indicating the required number of turns for proper compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If finger tightening method is used to tighten nuts, then ease of operation is improved, but manufacturing precision deteriorates due to subjective interpretation and inconsistent torque application
Solution Approach 1:
The patent replaces the subjective mechanical finger-tightening method with an electronic sensor system that objectively measures and controls the tightening process. Strain gauges and gyroscopes monitor the actual tightening parameters, substituting human judgment with precise electronic measurement to achieve consistent, accurate tightening without requiring subjective interpretation of 'finger tight' conditions.
Solution Approach 2:
The patent implements a feedback mechanism where strain gauges continuously monitor the tightening force and provide real-time data to indicate when the desired tightening condition is achieved. The system gives visual or audible feedback to the operator, allowing them to stop tightening at the precise moment the target compression is reached, thereby eliminating over-tightening while maintaining ease of operation.
2Reliability
If nuts are overtightened to ensure sealing, then reliability is improved, but strength deteriorates due to stress-induced component failure
Solution Approach 1:
The strain gauge system provides real-time feedback on the compression force applied to the gasket and components. When the pre-determined optimal compression level is reached, the system signals the operator to stop tightening, ensuring reliable sealing while preventing the excessive force that would cause stress-induced component failure or weld damage.
Solution Approach 2:
The patent changes the physical parameter being controlled from subjective torque application to objectively measured strain/compression. By monitoring the actual deformation of components during tightening, the system maintains the precise compression parameter needed for sealing while preventing parameter excursions that would lead to component failure.
3Manufacturing precision
If multiple turns of nuts are used to ensure full contact, then manufacturing precision is improved, but time consumption increases
Solution Approach 1:
The gyroscope and strain gauge system continuously monitors alignment and contact conditions during tightening. The feedback mechanism detects when full gland-to-gland contact is achieved, allowing the operator to stop the tightening process at the precise moment alignment is complete. This eliminates the need for conservative over-tightening through multiple turns, achieving full contact precision without unnecessary time consumption.
4Manufacturing precision
If strain monitoring system is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment and measurement devices with electronic sensors (strain gauges and gyroscopes) that are integrated into the existing wrench or tightening tool. This substitution achieves high manufacturing precision through electronic measurement while keeping the overall device complexity manageable by using modern electronic components rather than elaborate mechanical systems.
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
This solution ensures consistent and accurate tightening of fluid connections, reducing the risk of leaks and stress on components, thereby enhancing safety and reliability in industrial applications.
Implementation Method 1
A wrench capable of monitoring the strain on the body of the wrench used to tighten the nut(s) of the fitting
Implementation Method 2
A wrench equipped with strain gauges and a gyroscope that monitors the strain during tightening
Data Source
AI summary
A wrench and method of using the wrench to properly make up threaded connections is provided. The wrench includes at least a strain gauge coupled thereto, such that when the wrench is used to turn one part of a threaded connection, the strain associated with different states of the making up of the connection is monitored, to establish a baseline condition after which the one part of the threaded connection is turned an additional number of degrees, turns, or fractions of a turn. The wrench and method may be used to make up fluid tight connections, where previously the threaded parts were finger tightened, followed by turning thereof an additional number of degrees, turns, or fractions of a turn.