Shear Wrench Current-Signal Detection for Fastener Usage Tracking
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Solution Overview
Problem
Power tools, such as shear wrenches, lack effective methods to accurately assess their operation, including usage metrics like socket usage and fastener counts, which hinders the evaluation of tool lifetime, efficiency, and job site productivity.
Innovation Solution
A shear wrench equipped with a motor, current sensor, and electronic controller that analyzes current data to generate shear indications, including fastener size, count, and location, using thresholds and current change rates, and communicates this data wirelessly or via a network to an external device for comprehensive operation assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If power tools are equipped with sensors and electronic controllers to track operation metrics, then measurement precision of tool usage is improved, but device complexity increases
Solution Approach 1:
The motor serves multiple functions: it provides the primary driving force for the shear wrench operation and simultaneously acts as a sensor through its current draw to detect shear events. This multi-functionality eliminates the need for separate sensing components, reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The system uses its own operational parameters (motor current) to assess its operation. The motor's electrical characteristics during operation provide inherent information about shear events, eliminating the need for external or additional sensing systems and simplifying the overall device architecture.
2Measurement precision
If current sensors and data analysis systems are added to detect shear events, then measurement precision of shear detection is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical sensing systems with electrical field-based detection. By monitoring motor current, the system detects shear events through electrical parameters rather than mechanical sensors, simplifying the electronic system while improving measurement precision.
Solution Approach 2:
The motor current serves as an intermediary that translates mechanical shear events into electrical signals. This intermediary approach allows the system to detect shear events indirectly through electrical measurements, avoiding the need for direct mechanical contact sensors and reducing system complexity.
3Loss of information
If detailed usage metrics are collected and analyzed, then information completeness about tool performance is improved, but loss of energy increases due to data processing
Solution Approach 1:
The system collects only the specific electrical parameters needed for shear detection (motor current) rather than comprehensive operational data. This selective data collection approach provides sufficient information for performance assessment while minimizing energy consumption associated with data acquisition and processing.
Solution Approach 2:
The patent extracts only the essential information (shear detection from motor current) from the available data stream, discarding unnecessary data collection and processing. This extraction approach maintains information completeness for the specific application while reducing energy consumption.
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
Enables accurate and efficient assessment of power tool operation, improving the evaluation of tool lifetime, efficiency, and job site productivity by providing detailed usage metrics and real-time data analysis.
Implementation Method 1
a current sensor configured to detect motor current
Data Source
AI summary
A power tool including a shear wrench and method for tool operation assessment is disclosed. A shear wrench may include a motor, a current sensor configured to detect motor current, and an electronic controller including a processor and a memory. The electronic controller may drive the motor in response to an actuation, receive current data from the current sensor when the motor is driven in response to the actuation, and generate a shear indication indicating detection of a shear based on analysis of the current data. Other aspects, embodiment, and features are also claimed and described.