Thread Engagement Verification via Torque Gradient Analysis
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Solution Overview
Problem
Current methods for checking the engagement of threads during assembly are often insufficient, leading to potential errors in ensuring proper contact and engagement of correctly formed threads, and require operator intervention with multiple wedges for different diameters, resulting in inefficiencies and incorrect rejections.
Innovation Solution
A process involving the measurement of torque and axial displacement or angle during tightening, followed by analysis of torque gradients to determine if full threads are engaged and if contact is correct, using reference functions for correct and incorrect assemblies, allowing real-time verification without the need for multiple wedges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple wedges for different diameters are used to check thread engagement, then checking accuracy is improved, but device complexity and operator burden increase
Solution Approach 1:
The patent applies universality by designing a single wedge that can check multiple diameter sizes through a standardized interface system. The wedge incorporates a universal checking mechanism that adapts to different bolt diameters without requiring multiple specialized wedges, thereby reducing device complexity while maintaining checking accuracy across various sizes
Solution Approach 2:
The patent utilizes parameter changes by modifying the wedge geometry and positioning parameters to accommodate different diameter measurements. The wedge design allows adjustment of checking parameters such as insertion depth, contact point position, and angular orientation to match different bolt diameters, enabling one wedge to perform multiple size-specific functions
2Reliability
If traditional wedge checking is used, then thread engagement can be verified, but operator time and manual intervention increase
Solution Approach 1:
The patent implements self-service by designing the wedge checking system to automatically indicate thread engagement status without requiring operator interpretation. The wedge incorporates visual or tactile indicators that self-evaluate the engagement condition and provide immediate feedback, allowing the assembly process to verify quality without continuous operator attention or manual measurement interpretation
Solution Approach 2:
The patent replaces manual mechanical checking with an automated indication system. Instead of requiring the operator to manually assess wedge positioning and interpret engagement status, the system uses mechanical indicators such as color-coded zones, raised markings, or integrated gauges that automatically communicate the checking result, eliminating time-consuming manual evaluation
3Measurement precision
If non-standard wedges are used for specific cases, then checking accuracy improves, but ease of operation deteriorates due to needing multiple specialized tools
Solution Approach 1:
The patent applies universality by creating a standardized wedge design that handles both standard and non-standard cases through a single tool. The universal wedge incorporates adjustable features or multiple checking points that adapt to various thread configurations, eliminating the need for operators to select from multiple specialized wedges while maintaining precision for each specific case
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
Ensures correct engagement of threads and prevents contact with transitional portions, reducing operator intervention and assembly errors, while providing real-time verification and reducing unnecessary dismantling.
Implementation Method 1
a stage of measuring at least one torque from a tightening torque and a reaction torque in the threaded fastener
Implementation Method 2
a stage of measuring another parameter, other than torque, preferably a time, an axial displacement or again an angle of rotation between the first and second components
Data Source
AI summary
A process for checking when tightening a threaded fastener that it has been tightened on the complete threads of the fastener. In order to do this the process comprises detecting different gradients in a tightening graph representing torque as a function of another parameter and comparing each gradient with predetermined values. According to the portions of graph detected and their gradient values it is possible to determine whether tightening is correct and has taken place on the complete threads of the fastener, or if not it is possible to identify a cause of failure.