Tightening Tool Posture Detection for Bolt Accuracy
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Solution Overview
Problem
Conventional tightening tools do not accurately consider the posture of the tool during the tightening process, leading to inconsistencies in the accuracy of bolt or screw tightening.
Innovation Solution
A tightening tool control system that includes a control device and a tool capable of detecting and registering the tightening posture, determining a proper range for tightening, and adjusting its operation based on this data to ensure accurate positioning and prevent improper tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tightening tools are used without posture detection, then the device complexity is low, but the manufacturing precision of tightening is insufficient
Solution Approach 1:
The patent replaces mechanical posture control methods with sensor-based detection systems (acceleration sensors, gyro sensors) and electronic control mechanisms. This substitution enables precise tightening accuracy through digital sensing and processing while managing system complexity through integrated control units that coordinate multiple sensors and actuators.
Solution Approach 2:
The control device serves as an intermediary between the sensors (detecting posture and hand shaking) and the tightening mechanism. It processes sensor data, determines appropriate tightening parameters, and controls the actuator accordingly, thereby achieving high tightening precision without requiring direct complex mechanical linkages between sensing and actuation components.
2Manufacturing precision
If tightening control is based only on hand shaking detection, then the ease of operation is maintained, but the manufacturing precision of tightening deteriorates
Solution Approach 1:
The control device performs multiple functions: it processes hand shaking data from acceleration sensors, analyzes posture information from gyro sensors, determines tightening parameters, and controls the tightening actuator. This multi-functionality integrates various detection and control tasks into a single system, maintaining ease of operation while achieving high tightening precision through comprehensive data processing.
Solution Approach 2:
The system implements feedback by continuously monitoring hand shaking and posture through sensors, comparing detected values against target ranges, and adjusting tightening control accordingly. The control device uses feedback from acceleration and gyro sensors to dynamically modify tightening parameters, ensuring high accuracy while requiring minimal operator intervention beyond initiating the process.
3Reliability
If the tightening tool registers and determines proper range based on multiple tightening postures, then the reliability of tightening is improved, but the loss of time increases
Solution Approach 1:
The control device performs preliminary determination of the proper tightening posture range by analyzing multiple registered tightening postures before actual tightening operations. This advance preparation of reference data enables faster real-time decisions during tightening, improving reliability through thorough analysis while reducing time loss during production by having criteria ready beforehand.
Solution Approach 2:
The system collects and analyzes a sufficient number of tightening posture samples to establish a reliable proper range, potentially exceeding the minimum necessary data points. This excessive action in data collection ensures high reliability of the determined range, while the efficient processing algorithms minimize the time required, balancing thoroughness with speed in determining acceptable tightening postures.
Data Source
AI summary
There is provided a tightening tool control system including a tightening tool and a PC (Personal Computer) for controlling the tightening tool, the tightening tool having a registration mode for detecting a tightening posture when tightening a member and for registering the detected tightening posture in the PC.