Swing Torque Sensing With Modular Drive Head Interfaces
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Solution Overview
Problem
Conventional torque wrenches with changeable drive heads are limited by high costs, require multiple tools for different fastening processes, and necessitate complex calibration due to varying fitting structures, leading to inefficiency and increased expenses.
Innovation Solution
A modular swing torque sensing and transmitting device with adaptable fitting structures at both ends, allowing connection to different drive heads, equipped with a torque sensing unit, circuit board module, and battery module, capable of digital torque sensing and display, and enabling data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a torque sensing component is fixed to the grip of a torque wrench, then torque sensing capability is achieved, but the device cannot adapt to different drive heads with varying fitting structures
Solution Approach 1:
The torque wrench is divided into separate modular components: a grip module with a first fitting structure, a drive head module with a second fitting structure, and a connecting module with intermediate fitting structures. This segmentation allows each module to be independently designed and matched to specific applications while maintaining overall system versatility.
Solution Approach 2:
The connecting module incorporates multiple types of fitting structures (e.g., hexagonal, square, dovetail) that can interface with different drive head types. This universal design enables a single torque wrench body to accommodate various drive heads through the interchangeable connecting modules, eliminating the need for multiple specialized wrenches.
2Adaptability or versatility
If multiple torque wrenches with different fitting structures are purchased to cover different fastening processes, then versatility is achieved, but production cost and inventory expenses increase
Solution Approach 1:
Multiple torque wrench designs are merged into a single unified platform by using a common grip module combined with interchangeable connecting modules and drive heads. This consolidation allows one base tool to perform the functions of multiple specialized wrenches, reducing the total number of tools needed from several complete wrenches to one wrench with multiple attachments.
Solution Approach 2:
The universal torque wrench design incorporates a standardized interface system that accepts various drive head types (hexagonal, square, dovetail, etc.) through the connecting module. This multi-functional capability enables a single tool to cover diverse fastening processes that previously required multiple dedicated tools, thereby reducing inventory quantity while maintaining comprehensive functionality.
3Adaptability or versatility
If conventional torque wrenches with changeable drive heads are used, then versatility is improved, but calibration complexity increases due to varying fitting structures
Solution Approach 1:
The connecting module is pre-configured with standardized fitting structures and corresponding torque transmission characteristics during manufacturing. This preliminary setup includes pre-calibrated mechanical interfaces that ensure consistent torque transmission across different drive head types, eliminating the need for field calibration when switching between configurations.
Solution Approach 2:
The system manages parameter variations through standardized interface designs where the mechanical properties (such as engagement geometry and force transmission paths) are optimized to maintain consistent torque characteristics. By controlling the geometric parameters of the fitting structures, the system achieves versatility without requiring recalibration for different drive head types.
4Measurement precision
If digital display-style torque wrenches with fixed torque sensing components are used, then torque measurement precision is achieved, but adaptability to different drive heads is lost
Solution Approach 1:
The torque sensing system is segmented and repositioned through the modular connecting module structure. The sensing component remains fixed relative to the grip for precise measurement, while the modular connecting module provides the adaptability interface. This segmentation allows the sensing system to maintain its precision position while the mechanical interface adapts to different drive heads.
Solution Approach 2:
The connecting module serves as an intermediary between the fixed torque sensing system in the grip and the variable drive head interfaces. This intermediate component transmits torque accurately from the sensing location to the drive head while accommodating different fitting structures, thereby bridging the contradiction between measurement precision and adaptability.
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
Enhances flexibility and reduces costs by allowing universal use across different drive heads, simplifies calibration, and supports data recording and transmission, improving operational efficiency and reducing inventory.
Implementation Method 1
a deformation sensing signal generated by the torque sensing unit because of a bend of the sensing shaft under a force
Implementation Method 2
a strain gauge, is attached and fixed to a fixed position on the grip of a digital display-style wrench to detect the deformation of the sensing shaft because of a bend thereof under a pushing force or a pulling force
Data Source
AI summary
A swing torque sensing and transmitting device, flexibly mounted between the grip of a torque tool and the drive head of a bolt or nut, includes a sensing shaft, a torque sensing unit, a battery cover plate, two outer housings, a circuit board module and a battery module. A battery cover plate holds the battery module inside a housing. The circuit board module is set in another housing. The device is swinging in the process of tightening or un-tightening the threaded fastener, by sensing the deformation sensing signal caused by the body bending due to pushing or pulling, which is amplified by the circuit board module, and continuously calculates the applied torque and angular movement of the device, and when the target torque or angle displacement is reached, an audible and visual warning is given while the result is displayed, recorded or uploaded at the same time.