Sensorized Fasteners for Remote Torque Monitoring and Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mechanical fasteners and drivers often cause stripping or breaking of fasteners due to over-torquing, leading to difficulties in removal and increased costs, as existing technologies lack effective methods for remotely monitoring and managing torque and fastener conditions.
Innovation Solution
The implementation of a control system with sensors embedded in or around fasteners and structural materials to monitor conditions, applying remote torque and taking remedial actions, along with powered driver bits that detect proper seating and adjust power delivery to prevent over-torquing, and the use of multiple-section fasteners that self-tighten and break away to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional mechanical drivers are used to tighten fasteners, then fastening operations can be performed, but fastener stripping or breaking occurs due to over-torquing
Solution Approach 1:
The patent implements feedback mechanisms through torque sensors that continuously monitor the torque applied during fastening operations. When the sensor detects that the applied torque approaches or exceeds the fastener's torque capacity, the system automatically adjusts or stops the driving force, preventing over-torquing and subsequent fastener damage.
Solution Approach 2:
The patent replaces traditional purely mechanical driver systems with an integrated electromechanical system that incorporates electronic torque sensing and control. This substitution allows for precise torque monitoring and automated adjustment, eliminating the need for manual torque estimation and preventing mechanical failure from over-torquing.
2Reliability
If higher torque is applied to ensure fastener tightness, then fastening reliability improves, but the risk of fastener breaking increases
Solution Approach 1:
The patent replaces manual torque control with an automated electromechanical system that uses electronic sensors to precisely monitor and control applied torque. This substitution ensures that the optimal torque is applied to achieve reliable fastening without exceeding the fastener's strength limits, preventing breaking while ensuring tightness.
Solution Approach 2:
The patent dynamically adjusts the torque parameter during the fastening process based on real-time feedback from torque sensors. The system monitors torque application and automatically modifies the driving force to maintain torque within safe limits, ensuring both fastener tightness and integrity throughout the operation.
3Object-affected harmful factors
If torque wrenches with preset torque limits are used, then over-torquing is prevented, but remote monitoring and management of fastener conditions is not possible
Solution Approach 1:
The patent integrates multiple functions into a single driver system, combining torque application, real-time torque monitoring, data communication, and remote management capabilities. This multi-functional system not only prevents over-torquing but also enables remote monitoring of fastener conditions and torque history, eliminating the need for separate monitoring equipment.
Solution Approach 2:
The patent replaces simple mechanical torque wrenches with an intelligent electromechanical system that incorporates electronic sensors, processors, and communication interfaces. This substitution transforms a basic torque-limiting device into a sophisticated system capable of real-time monitoring, data transmission, and remote management of fastener conditions.
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 effectively reduces fastener stripping and damage by remotely monitoring and managing torque, allowing for precise control of fastening operations, thereby minimizing collateral damage and costs associated with removing stripped or broken fasteners.
Implementation Method 1
such sensor(s) include a magnetizable array, which may include one or more charge-carrying and/or otherwise magnetic projections... In some embodiments, such remote monitoring includes testing a magnetic signature of the fastener and/or structural material
Data Source
AI summary
Improved techniques for remotely monitoring and managing fasteners and fastener driver conditions, are provided. In some aspects of the invention, conditions of a fastener and/or structural material(s) held by the fastener and/or connector, are monitored by a control system including sensor(s) at least partially embedded in, on or throughout the fastener and/or structural material(s). When an adverse condition is sensed, a torque may be remotely applied to the fastener, in some embodiments. In some embodiments, other remedial actions may be taken by the control system. In some embodiments, such sensor(s) include a magnetizable array, which may include one or more charge-carrying and/or otherwise magnetic wires or particles on, about, or embedded within, the fastener and/or structural material. In some embodiments, such remote monitoring includes testing a magnetic signature of the fastener and/or structural material (e.g., via remote scanning and/or testing).