Torque Control System for Power Impact Tools
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Solution Overview
Problem
Conventional power impact torque tools face challenges in maintaining stable torque control due to factors like power output degradation, wear of impact mechanisms, temperature changes, and variations in workpiece hardness, leading to inconsistent tightening results.
Innovation Solution
A torque control system and method that continuously monitors and adjusts the working voltage or current using a microprocessor and sensing elements to maintain the torque within a preset range, employing a calibration process to establish a relationship curve between voltage/current and torque, enabling closed-loop control and precise tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power impact torque tools are used without continuous voltage monitoring and adjustment, then the device complexity is reduced, but the torque control stability deteriorates due to power output degradation, wear, temperature changes, and workpiece variations
Solution Approach 1:
The patent implements a closed-loop feedback control system where a sensing element continuously detects the actual torque or working parameters, feeds this information back to a microprocessor, and the microprocessor adjusts the working voltage in real-time to maintain stable torque output despite external disturbances such as power degradation, wear, temperature changes, and workpiece variations.
Solution Approach 2:
The patent replaces conventional mechanical torque control mechanisms with an electronic control system. Instead of relying on mechanical adjustments and open-loop control, the system uses electronic sensing elements, microprocessors, and voltage regulation circuits to achieve precise and adaptive torque control, thereby improving reliability while managing complexity through electronic rather than mechanical means.
2Manufacturing precision
If a torque sensing device is built-in to enable closed-loop control, then the torque control precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces a torque sensing device as an intermediary element between the impact mechanism and the output shaft. This sensing device detects torque or angular parameters and converts them into electrical signals that can be processed by the microprocessor, enabling precise closed-loop control without requiring complex mechanical feedback mechanisms.
Solution Approach 2:
The patent substitutes mechanical torque measurement and feedback mechanisms with electronic sensing and signal processing. The torque sensing device, combined with the microprocessor and voltage control module, creates an electronic control system that achieves high torque control precision while avoiding the complexity of purely mechanical feedback systems.
3Reliability
If the working voltage is not stabilized during operation, then the ease of operation is maintained, but the torque consistency deteriorates due to power output degradation and temperature changes
Solution Approach 1:
The patent implements a self-regulating voltage control system where the microprocessor continuously monitors working parameters through the sensing element and automatically adjusts the working voltage to maintain consistent torque output. This self-service mechanism compensates for power degradation, temperature changes, and other operational variations without requiring manual intervention, thereby maintaining torque consistency while preserving ease of operation.
Solution Approach 2:
The patent uses real-time feedback from the sensing element to detect changes in working conditions and adjusts the voltage accordingly. This automatic feedback loop ensures torque consistency throughout operation without requiring the operator to manually adjust settings, thus maintaining both reliability and ease of operation.
Data Source
AI summary
In a torque control system and method for power impact torque tool, first establish a curve showing the relationship between the high/low working voltages of the tool in normal operation and the high/low torque values that are correspondingly output by the tool at the high/low working voltages. Input a target torque value that falls between the highest and the lowest torque value on the relationship curve to obtain a working voltage corresponding to the target torque value for performing a tightening operation. During the tightening process, a microprocessor of a torque control device receives and uses sensing signals instantly and continuously sent by a torque sensing device and changes in voltage, current and motor temperature continuously detected by a voltage/current sensing element and a temperature sensing element to stably control, via a voltage control module, the working voltage within a preset allowable range of variation for tightening torque control.