Tightening Tool Energy Flow Monitoring for Early Failure Detection

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Solution Overview

Problem

Current tightening tool systems lack effective monitoring for impending tool failures, material variations, and operator behavior, leading to production disturbances due to the difficulty in obtaining a comprehensive overview of assembly lines.

Innovation Solution

A method and monitoring node that calculates energy flow in tightening tools by receiving parameter values such as current, rotor angle, and torque, detecting deviations, and transmitting alarm messages to prevent failures and inefficiencies, while also considering temperature and desired torque settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If production technicians manually observe operators and error codes to gain overview of assembly line, then they can detect problems with tool usage and operator behavior, but it requires a lot of experience and time, and it is impossible to observe the whole assembly line at once

Engineering Contradiction:

Improvedetection capabilityVSAvoidtime for observation

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent introduces an intermediary system consisting of monitoring nodes and a server that automatically collect, process, and analyze data from tightening tools. This intermediary infrastructure enables comprehensive monitoring of the entire assembly line without requiring technicians to manually observe each station, thus resolving the contradiction between detection capability and time consumption.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the manual mechanical observation process with an automated electronic monitoring system. Sensors and communication networks substitute for human technicians physically moving between stations, enabling continuous comprehensive monitoring without time loss and maintaining high detection capability through automated analysis of tool parameters and error codes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If production technicians manually observe each station of the assembly line, then they can detect problems, but it is impossible to observe the whole assembly line at once leading to production failures

Engineering Contradiction:

Improvedetection capabilityVSAvoidproduction continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The monitoring system performs multiple functions simultaneously: it collects data from all tightening tools, analyzes energy flow patterns, detects anomalies, and generates alerts. This multi-functional approach enables comprehensive monitoring of the entire assembly line at once, maintaining detection capability while ensuring production continuity through proactive problem identification.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements continuous monitoring of assembly line operations through always-active sensors and data collection mechanisms. This continuous useful action ensures that the entire assembly line is under observation at all times, preventing production failures by detecting issues as they emerge rather than through intermittent manual checks.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If no energy flow monitoring is implemented, then the system is simpler, but impending tool failures, material variations, and operator behavior cannot be foreseen or detected

Engineering Contradiction:

Improvefailure prediction capabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements feedback mechanisms where monitoring nodes continuously measure energy flow parameters, compare them against expected values, and trigger alerts when deviations indicate potential failures. This feedback loop enables failure prediction by analyzing patterns in energy consumption, while the automated nature of the feedback reduces the operational complexity despite the added monitoring infrastructure.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The monitoring system performs preliminary analysis of energy flow data to identify trends and patterns that precede tool failures, material variations, or operator issues. By detecting these preliminary indicators before actual failures occur, the system enables proactive maintenance and intervention, improving reliability while the automated preliminary detection reduces the complexity of manual analysis.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11285590B2Method, monitoring node and computer program of monitoring energy flow in a tightening tool

Publication Date: 2022.03.29 ATLAS COPCO IND TECHNIQUE AB INTELLECTUAL PROPERTY DEPARTMENT

AI summary

A method performed by a monitoring node associated with a tool communication network of monitoring energy flow in a tightening tool connected to the communication network includes receiving, from the tightening tool, parameter values relating to current fed (I) into the tightening tool, angle (α) of a rotor in the tightening tool and torque (T) applied to a joint by the tightening tool. The method also includes calculating energy input to the tightening tool based on the received parameter values, calculating energy transferred to the joint by the tightening tool based on the received parameter values relating to the torque applied to the joint by the tightening tool and the angle (α) of the rotor in the tightening tool. The method further includes detecting that the calculated energy input deviates from the calculated energy transferred to the joint by more than a predetermined value.