Threaded Insert Alignment Using Torque-Guided Spline Engagement
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Solution Overview
Problem
The manual alignment and swaging of thin-walled inserts in holes is time-consuming and requires precise manual operations, which can be inefficient and prone to errors.
Innovation Solution
An apparatus and method that utilize a driver, torque measurement device, and controller to automatically align and secure inserts by rotating them until the splines are level with grooves, applying a test torque to verify the securement, and using a swaging tool to deform the insert for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and swaging operations are used, then the process can be performed with simple tools, but the operation time increases and precision decreases
Solution Approach 1:
The patent combines multiple functions (alignment, torque measurement, swaging, and verification) into a single integrated automated apparatus. The driver assembly integrates rotation control, torque sensing, and depth control, while the swaging tool is coordinated with the driver to perform sequential operations automatically, eliminating the need for separate manual operations.
Solution Approach 2:
The apparatus performs self-verification through the torque sensor that automatically detects when the insert is properly secured by monitoring torque values during and after swaging. The system self-adjusts and self-verifies without requiring external inspection or manual testing, achieving autonomous operation.
2Measurement precision
If manual alignment using magnifying glass is used, then the equipment remains simple, but alignment precision and reliability decrease
Solution Approach 1:
The patent replaces manual visual alignment (mechanical/optical method) with an automated driver system that uses torque measurement feedback to precisely control the rotation and positioning of the insert. The torque sensor provides real-time feedback to automatically determine when splines are properly aligned with grooves, eliminating the need for magnifying glass inspection.
Solution Approach 2:
The torque sensor provides continuous feedback during the insertion and swaging process, allowing the controller to automatically adjust the driver's rotation and stopping position. This feedback mechanism ensures precise alignment by detecting torque variations that indicate proper spline-groove engagement, replacing manual visual assessment.
3Reliability
If manual swaging with hammer and punch is used, then the tooling remains simple, but the securesment reliability and consistency decrease
Solution Approach 1:
The patent replaces manual hammer and punch swaging with an automated swaging tool integrated into the driver assembly. This automated tool applies controlled radial forces to deform the insert walls uniformly, ensuring consistent engagement with the hole walls without the variability inherent in manual hammering.
Solution Approach 2:
The torque sensor provides automatic verification of securement by monitoring torque values after swaging. The system self-verifies that the insert is properly secured by detecting the torque required to rotate the insert post-swaging, eliminating the need for separate manual torque testing.
4Loss of time
If automated driver with torque sensor is used, then the operation time decreases, but the apparatus complexity increases
Solution Approach 1:
The patent combines the driver, torque sensor, swaging tool, and control system into a single integrated apparatus that performs multiple operations (insertion, alignment, swaging, and verification) in one automated sequence. This integration eliminates the need for multiple separate tools and manual transitions between operations, reducing total operation time despite the increased complexity of the integrated system.
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 approach automates the alignment and securement process, reducing manual effort and increasing precision, thereby improving efficiency and ensuring accurate positioning of inserts in holes.
Implementation Method 1
a torque measurement device arranged to measure the driving torque applied by the driver
Implementation Method 2
the insert is swaged (i.e. deformed using a tool) such that the splines engage with the grooves
Data Source
AI summary
An apparatus for securing an insert in a hole, the insert having an axis, a section comprising a thread disposed around the axis and a section comprising a plurality of splines, and the hole having a section comprising a corresponding thread and a section comprising a plurality of grooves corresponding to said splines, the apparatus comprising a driver arranged to rotate the insert, a torque measurement device arranged to measure the driving torque applied by the driver, and a controller arranged to cause the driver to drive the insert into the hole until the splines are level in the axial direction with the grooves by rotating the insert in a first direction, and align the splines with the grooves by causing the driver to further rotate the threaded insert whilst measuring the driving torque using the torque measuring device, and stopping the further rotation based on the measured driving torque.