Torque Calibration System Using Master Tool and Inline Transducer
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Solution Overview
Problem
Current methods for calibrating torque tools are time-consuming, prone to errors, and do not provide a repeatable torque joint, as they rely on manual recordation and the use of spring or washer stacks, which require unwinding and are not accurate.
Innovation Solution
A system and method using a master torque tool with a torque engagement mechanism to automatically collect and measure torque and angular data, generating updated calibration factors and certification, which includes a rotary inline torque transducer and a software package to automate the calibration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual recordation and spring/washer stack methods are used for calibration, then the process is simple to set up, but the calibration is time-consuming and prone to errors
Solution Approach 1:
The patent replaces manual recordation and mechanical spring/washer stack systems with an automated digital measurement and control system. The automated system uses electronic sensors and software to collect, record, and process calibration data, eliminating manual operations and their associated errors while maintaining high measurement precision through consistent automated measurement protocols.
Solution Approach 2:
The calibration system performs self-calibration by automatically comparing measurements from the torque tool under test against reference standards stored in the system. The software autonomously processes data, calculates calibration factors, and generates certification without requiring manual intervention, thereby increasing both speed and accuracy.
2Reliability
If spring or washer stacks are used to simulate joints, then the setup is simple, but the torque joint is not repeatable and requires unwinding between tests
Solution Approach 1:
The patent implements a continuous calibration capability where the simulated joint mechanism remains in place and can be repeatedly tested without disassembly or unwinding. The system maintains continuous measurement capability across multiple calibration iterations, eliminating downtime between tests and ensuring consistent joint characteristics through controlled simulation.
Solution Approach 2:
The system uses a controlled simulated joint mechanism as an intermediary that provides consistent, repeatable torque characteristics. This intermediary joint simulation replaces variable spring/washer stacks with a controlled system that can be precisely actuated and measured, ensuring repeatable test conditions across all calibration iterations.
3Productivity
If manual recordation of torque measurements is used, then the equipment complexity is low, but the process is time-consuming and prone to input errors
Solution Approach 1:
The patent replaces manual recordation processes with automated electronic data acquisition and processing systems. Sensors, data loggers, and software work together to automatically capture torque measurements, eliminate manual transcription errors, and rapidly process calibration data, significantly increasing throughput despite the added electronic system complexity.
Solution Approach 2:
The calibration system automatically performs data collection, analysis, and certification generation without manual intervention. The software autonomously processes measurement data, calculates calibration factors, validates results, and produces certification documents, thereby increasing productivity while the added complexity is managed through integrated automation.
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 allows for accurate, efficient, and automated calibration of torque devices, reducing manual errors and downtime, and enabling serial calibration without the need for repeated deadweight calibrations.
Implementation Method 1
a rotary inline torque transducer engaged with a square drive of the master torque tool
Data Source
AI summary
Methods and associated system for calibrating a torque device are provided. The method includes (I) providing a master torque tool having an accepted calibration, (II) attaching the torque device to be calibrated to an input shaft of a testing and calibration system, (III) energizing the torque device to a free spin under a no load and zero torque condition, (IV) performing a run down test by activating a torque engagement mechanism to transferred torque from the torque device to the master torque tool, (V) measuring a torque value from the master torque tool, the torque device, and the rotary inline torque transducer to generate a data set, (IX) repeating steps (IV) to generate a plurality of data sets and (V), and (VI) generating new calibration factors for input into a programmable control system of the torque device based on the plurality of data sets with a software package.