Tilt Compensated Torque-Angle Wrench Flex Error Correction
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Solution Overview
Problem
Flexing of torque wrench heads introduces errors in torque and angle measurements due to the wrench body and sensor turning in different planes than the fastener, leading to inaccuracies in measurement.
Innovation Solution
A method using sensors to determine the rotational angle, tilt, and measured torque, with a processor adjusting the measured torque by a factor based on the ratio of tool length to reaction distance, accounting for the flex angle and tilt to provide accurate fastener torque and angle measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flex head is used to allow the wrench body to pivot and clear components, then ease of operation is improved, but measurement precision deteriorates due to errors in torque and angle measurements
Solution Approach 1:
The system uses sensors to detect the actual tilt angle of the wrench body relative to the fastener, and feeds this information back to a controller that calculates correction factors. These correction factors are applied to the measured torque and angle values to compensate for the flex head-induced measurement errors, allowing accurate measurements even when the flex head is pivoted
Solution Approach 2:
The system dynamically changes the measurement parameters by calculating correction factors based on the detected tilt angle. The correction factors adjust the effective torque and angle measurements to account for the flex head position, transforming the inaccurate measurements into accurate fastener torque and angle values through mathematical parameter adjustment
2Adaptability or versatility
If the wrench body turns in a different plane than the fastener due to flexing, then adaptability is improved, but measurement precision deteriorates because the sensor and wrench body are not aligned with the fastener
Solution Approach 1:
The system adds a third dimension to the measurement by detecting the tilt angle in the vertical plane (yaw axis) in addition to the horizontal plane (roll axis). This dimensional addition allows the system to calculate the actual fastener torque and angle by compensating for the plane difference between the wrench body and fastener, maintaining measurement precision across multiple operational dimensions
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 compensates for measurement inaccuracies caused by flexing, ensuring accurate torque and angle readings by integrating angular rates from multiple axes and adjusting for the effective length during torque application, thereby improving measurement precision.
Implementation Method 1
At least one sensor measures angular rates of rotation over both a yaw axis and a roll axis simultaneously
Implementation Method 2
Another sensor measures a torque of the tool
Data Source
AI summary
A method of determining an actual amount of torque and/or angle applied to a work piece by a tool. In an embodiment, the method includes determining a rotational angle, a tilt of the tool, and a measured torque of the tool. The actual amount of torque or angle applied to the work piece is then determined based on the rotational angle, the tilt, and the measured torque.